Manual de Servicio Elite+ PDF

dummyhead
How to use this manual

A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the
vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
0-1
dummyhead

How To Use This Manual
This manual describes the service procedures for the CHA125 3WH/4WH-E.
Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition.
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: May, 2013
0-2
dummyhead

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example:
• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Honda Moly 60 (U.S.A. only)
• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.
0-3
dummyhead
CONTENTS
GENERAL INFORMATION 1
FRAME/BODY PANELS/EXHAUST SYSTEM 2
MAINTENANCE 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE AND DRIVE TRAIN
ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH 9
FINAL REDUCTION 10
ALTERNATOR/STARTER CLUTCH 11
CRANKCASE/CRANKSHAFT 12
FRONT WHEEL/SUSPENSION/STEERING 13
CHASSIS
REAR WHEEL/SUSPENSION 14
BRAKE SYSTEM 15
BATTERY/CHARGING SYSTEM 16
ELECTRICAL
IGNITION SYSTEM 17
ELECTRIC STARTER 18
LIGHTS/METER/SWITCHES 19
WIRING DIAGRAM 20
TROUBLESHOOTING 21
INDEX
dummyhead
MEMO
dummytext
1. GENERAL INFORMATION
SERVICE RULES ··········································1-2 LUBRICATION & SEAL POINTS ··············· 1-11
MODEL IDENTIFICATION ····························1-2 CABLE & HARNESS ROUTING················· 1-13
SPECIFICATIONS ·········································1-3 EMISSION CONTROL SYSTEMS ·············· 1-25
TORQUE VALUES ········································1-7
1-1
dummyhead
GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design
specifications may cause damage to the scooter.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not interchangeable with English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-13).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
CBS Combined Brake System
SE thermal valve Starting Enrichment thermal valve
ICM Ignition Control Module
MODEL IDENTIFICATION
This manual covers 2 types of CHA125 models.
TYPE CODE COUNTRY BRAKE SYSTEM
LA Latin America Front disc brake/CBS type
AG Argentina Front disc brake/CBS type
CHA125 3WH
SA South Africa Front disc brake/CBS type
CO Columbia Front disc brake/CBS type
CHA125 4WH MX Mexico Front drum brake type
1-2
dummyhead
GENERAL INFORMATION
SERIAL NUMBERS/COLOR LABEL
V.I.N. (Vehicle Identification Number) ENGINE SERIAL NUMBER
COLOR LABEL
CARBURETOR IDENTIFICATION NUMBER
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATION
DIMENSIONS Except MX type 1860 mm (73.2 in)
Overall length
MX type 1828 mm (72.0 in)
Except MX type 679 mm (26.7 in)
Overall width
MX type 680 mm (26.8 in)
Overall height 1,108 mm (43.6 in)
Wheelbase 1,234 mm (48.6 in)
Seat height 749 mm (29.5 in)
Ground clearance 103 mm (4.1 in)
Curb weight Except MX type 117 kg (258 lbs)
MX type 116 kg (256 lbs)
FRAME Frame type Under bone
Front suspension Telescopic
Front axle travel 80 mm (3.1 in)
Rear suspension Unit swing
Rear axle travel 64 mm (2.5 in)
Front tire size 90/90 – 12 44J
Rear tire size 100/90 – 10 56J
Front tire brand C-922F (CHENG SHIN)
Rear tire brand C-922 (CHENG SHIN)
Front brake MX type Mechanical leading trailing
Except MX type Hydraulic single disc
Rear brake Mechanical leading trailing
Caster angle 27° 00’
Trail length 76 mm (3.0 in)
Fuel tank capacity 6.0 liter (1.59 US gal, 1.32 lmp gal)
1-3
dummyhead
GENERAL INFORMATION
ITEM SPECIFICATION
ENGINE Bore and stroke 52.4 x 57.8 mm (2.06 x 2.28 in)
Displacement 124.6 cm3 (7.60 cu-in)
Compression ratio 9.5 : 1
Valve train Chain driven, OHC
Intake valve opens at 1 mm lift 5° BTDC
closes at 1 mm lift 25° ABDC
Exhaust valve opens at 1 mm lift 30° BBDC
closes at 1 mm lift 5° ATDC
Lubrication system Forced pressure and wet sump
Oil pump type Trochoid
Cooling system Fan cooled
Air filtration Paper filter
Engine dry weight 29.3 kg (64.6 lbs)
CARBURETOR Carburetor type CV (Constant Velocity)
Throttle bore 24 mm (0.9 in)
DRIVE TRAIN Clutch system Dry, automatic centrifugal clutch
Drive belt ratio 2.640 – 0.860
Final reduction ratio 8.615
ELECTRICAL Ignition system DC-CDI
Starting system Electric starter motor/kickstarter
Charging system Single phase alternator
Regulator/rectifier SCR shorted/single phase, half-
wave rectification
Lighting system Alternator
LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil capacity After draining 0.9 liter (1.0 US qt, 0.8 lmp qt) –
After disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt) –
Recommended engine oil Honda 4-stroke oil or equivalent motor oil –
API service classification: SG or higher
JASO T 903 standard: MB
Viscosity: SAE 10W-30
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Carburetor identification number Except MX/CO type AVE4AG
MX/CO type AVE4AF
Main jet Except MX/CO type #110
MX/CO type #108
Slow jet #35
SE thermal valve resistance 4.5 Ω (20°C/68°F)
SE thermal valve resistor resistance 8.6 – 10.5 Ω (20°C/68°F)
Float level 18.5 mm (0.73 in)
Pilot screw initial opening See page 5-22
Engine idle speed 1,700 ± 100 min-1 (rpm)
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
1-4
dummyhead
GENERAL INFORMATION
CYLINDER HEAD/VALVES SPECIFICATIONS
Unit: mm (in)
Cylinder compression 1,275 kPa (13.0 kgf/cm2, 185 psi) –
at 570 min-1 (rpm)
Cylinder head warpage – 0.05 (0.002)
Valve clearance IN/EX 0.14 (0.006) –
Rocker arm Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Arm-to-shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.08 (0.003)
Camshaft Cam lobe height IN 29.375 – 29.615 (1.1565 – 1.1659) 29.30 (1.154)
EX 29.080 – 29.320 (1.1449 – 1.1543) 29.00 (1.142)
Valve, valve Valve stem O.D. IN 4.975– 4.990 (0.1959 – 0.1965) 4.90 (0.193)
guide EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
clearance EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Valve seat width IN/EX 1.0 (0.04) 1.6 (0.06)
Valve spring free length Inner 32.34 (1.273) 29.1 (1.15)
Outer 35.04 (1.380) 31.5 (1.24)
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
Cylinder I.D. 52.40 – 52.41 (2.0630 – 2.0634) 52.50 (2.067)
Out-of-round – 0.05 (0.002)
Taper – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston, Piston O.D. 52.370 – 52.390 (2.0618 – 2.0626) 52.30 (2.059)
piston ring, Piston O.D. measurement point 10 (0.39) from bottom of skirt –
piston pin Piston pin bore I.D. 15.002 – 15.008 (0.5906 – 0.5909) 15.04 (0.592)
Piston pin O.D. 14.994 – 15.000 (0.5903 – 0.5906) 14.96 (0.589)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Piston ring-to-ring groove Top 0.015 – 0.055 (0.0006 – 0.0022) 0.09 (0.004)
clearance Second 0.015 – 0.055 (0.0006 – 0.0022) 0.09 (0.004)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)
Second 0.15 – 0.30 (0.006 – 0.012) 0.60 (0.024)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) –
Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.10 (0.004)
Connecting rod small end I.D. 15.016 – 15.034 (0.5912 – 0.5919) 15.06 (0.593)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.06 (0.002)
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS

Unit: mm (in)
Drive belt width 20.0 (0.79) 19.0 (0.75)
Movable drive Bushing I.D. 23.989 – 24.052 (0.9444 – 0.9469) 24.07 (0.948)
face Boss O.D. 23.960 – 23.974 (0.9433 – 0.9439) 23.93 (0.942)
Weight roller O.D. 19.92 – 20.08 (0.784 – 0.791) 19.5 (0.77)
Clutch Lining thickness – 2.0 (0.08)
Clutch outer I.D. 125.0 – 125.2 (4.92 – 4.93) 125.5 (4.94)
Driven pulley Face spring free length 121.1 (4.77) 113 (4.4)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)
1-5
dummyhead
GENERAL INFORMATION
FINAL REDUCTION SPECIFICATIONS
ITEM SPECIFICATIONS
Final reduction oil After draining 0.19 liter (0.20 US qt, 0.17 lmp qt)
capacity After disassembly 0.20 liter (0.21 US qt, 0.18 lmp qt)
Recommended final reduction oil Honda 4-stroke oil or equivalent motor oil
CRANKCASE/CRANKSHAFT SPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
Runout – 0.10 (0.004)
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)
Minimum tire tread depth – To the indicator
Cold tire Driver only 175 kPa (1.75 kgf/cm2, 25 psi) –
pressure Driver and passenger 175 kPa (1.75 kgf/cm2, 25 psi) –
Axle runout – 0.2 (0.01)
Wheel rim Radial – 2.0 (0.08)
runout Axial – 2.0 (0.08)
Fork Spring free length 216.0 (8.50) 211.7 (8.33)
Pipe runout – 0.2 (0.01)
Recommended fluid Fork fluid –
Fluid level 59 (2.3) –
Fluid capacity 79 ± 2 cm3 (2.67 ± 0.07 US oz, –
2.78 ± 0.07 Imp oz)
REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)
Minimum tire tread depth – To the indicator
Cold tire Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
pressure Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) –
Wheel rim Radial – 2.0 (0.08)
runout Axial – 2.0 (0.08)
BRAKE SYSTEM SPECIFICATIONS

Unit: mm (in)
Front brake Specified brake fluid DOT 3 or DOT 4 –
(Except MX type) Brake disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Brake disc warpage – 0.10 (0.004)
Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755(0.5022)
Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4944) 12.645 (0.4978)
Caliper cylinder I.D. 27.000 – 27.050 (1.0630 – 1.0650) 27.060 (1.0654)
Caliper piston O.D. 26.918 – 26.968 (1.0598 – 1.0617) 26.91 (1.059)
Front brake Lever freeplay 10 – 20 (0.4 – 0.8) –

(MX type) Drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)
Rear brake Lever freeplay 10 – 20 (0.4 – 0.8) –
Drum I.D. 130.0 – 130.2 (5.12 – 5.13) 131.0 (5.16)
1-6
dummyhead
GENERAL INFORMATION
BATTERY/CHARGING SYSTEM SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Type YTX7L-BS
Capacity 12 V – 6 Ah
Current leakage 0.5 mA max.
Voltage Fully charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Charging Normal 0.6 A/5 – 10 h
current Quick 3.0 A/1.0 h
Alternator Capacity 0.13 kW/5,000 min-1 (rpm)
Charging coil resistance 0.2 – 1.0 Ω (20°C/68°F)
Lighting coil resistance 0.1 – 0.8 Ω (20°C/68°F)
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Spark plug Standard CR7HSA (NGK)
Optional CR6HSA (NGK)
Spark plug gap 0.60 – 0.70 mm (0.024 – 0.028 in)
Ignition coil peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F" mark) 15° BTDC at idle speed
ELECTRIC STARTER SPECIFICATIONS

Unit: mm (in)
Starter motor brush length 11.9 (0.47) 5.9 (0.23)
LIGHTS/METER/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight (Hi/Lo) 12 V – 35/35 W
Position light 12 V – 5 W
Brake/tail light 12 V – 21/5 W
License light 12 V – 5 W
Turn signal light 12 V – 21 W X 4
Meter light LED
Turn signal indicator 12 V – 3.4 W X 2
High beam indicator 12 V – 1.7 W
Fuse Main fuse 20 A
Sub fuse 15 A
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head; small head) 10 (1.0, 7)
10 mm bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head; large flange) 12 (1.2, 9)
12 mm bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)
8 mm flange bolt and nut 26 (2.7, 20)
10 mm flange bolt and nut 39 (4.0, 29)
1-7
dummyhead
GENERAL INFORMATION
ENGINE & FRAME TORQUE VALUES
• Torque specifications listed below are for specified fasteners.
• Others should be tightened to standard torque values listed above.
FRAME/BODY PANELS/EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Muffler protector bolt 2 6 10 (1.0, 7)
Exhaust pipe joint nut 2 7 29 (3.0, 22) For
tightening
sequence
(page 2-13)
Muffler mounting bolt 2 10 59 (6.0, 44) For
tightening
sequence
(page 2-13)
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
Spark plug 1 10 12 (1.2, 9)
Air cleaner housing cover screw 6 5 1.1 (0.1, 0.7)
Air cleaner element screw 1 – 4.2 (0.4, 3.1)
Valve adjusting lock nut 2 5 10 (1.0, 7) Apply engine
oil to the
threads and
seating
surface.
Engine oil drain plug 1 30 20 (2.0, 14)
Final reduction oil check bolt 1 8 13 (1.3, 10)
Final reduction oil drain bolt 1 8 13 (1.3, 10)
Equalizer connecting cable lock nut (Except MX type) 1 8 6.4 (0.7, 4.7)
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Oil pump plate screw 1 3 2 (0.2, 1.5)
FUEL SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Carburetor drain screw 1 – 1.5 (0.2, 1.1)
Inlet pipe band screw 1 – 4 (0.4, 3)
SE thermal valve set plate screw 2 4 2.1 (0.2, 1.5)
SE thermal valve body screw 2 5 3.4 (0.3, 2.5)
Throttle cable holder screw 2 5 3.4 (0.3, 2.5)
Vacuum chamber cover screw 2 4 2.1 (0.2, 1.5)
Float chamber screw 4 4 2.1 (0.2, 1.5)
Air cut-off valve cover screw 2 4 2.1 (0.2, 1.5)
Slow jet 1 – 1.8 (0.2, 1.3)
Needle jet holder 1 – 2.5 (0.3, 1.8)
Main jet 1 – 2.1 (0.2, 1.5)
Carburetor drain hose guide bolt 1 6 2 (0.2, 1.5)
Throttle cable clamp screw 2 6 2 (0.2, 1.5)
Fuel auto valve lock nut 1 16 18 (1.8, 13)
ENGINE REMOVAL/INSTALLATION
THREAD TORQUE
ITEM Q'TY REMARKS
Engine mounting bolt (frame side) 2 10 50 (5.1, 37)
Engine hanger bracket nut (engine side) 1 10 50 (5.1, 37)
1-8
dummyhead
GENERAL INFORMATION
CYLINDER HEAD/VALVES
THREAD TORQUE
ITEM Q'TY REMARKS
Cylinder head cover special bolt 2 6 12 (1.2, 9)
Cylinder head breather plate screw 3 4 3 (0.3, 2.2)
Camshaft holder nut 4 8 24 (2.4, 18) Apply engine
oil to the
threads and
seating
surface.
Intake shroud mounting bolt 2 6 8 (0.8, 5.9)
Intake shroud special bolt 1 6 13 (1.3, 10)
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

THREAD TORQUE
ITEM Q'TY REMARKS
Kickstarter pinch bolt 1 6 14 (1.4, 10)
Left crankcase cover bolt 8 6 10 (1.0, 7)
Drive pulley face nut 1 12 59 (6.0, 44) Apply engine
oil to the
threads and
seating
surface.
Clutch/driven pulley nut 1 28 54 (5.5, 40)
Clutch outer nut 1 12 49 (5.0, 36)
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM Q'TY REMARKS
Fan cover special bolt 2 6 8 (0.8, 5.9)
Flywheel nut 1 12 59 (6.0, 44)
Ignition pulse generator mounting bolt 2 5 6 (0.6, 4.4)
Oil pump cover bolt 2 6 12 (1.2, 9)
Stator mounting bolt 2 6 10 (1.0, 7)
Starter clutch lock nut 1 22 See page 11-9 Left hand
threads.
Apply engine
oil to the
threads and
seating
surface.
Starter clutch socket bolt 3 6 12 (1.2, 9) Apply locking
agent to the
threads.
CRANKCASE/CRANKSHAFT
THREAD TORQUE
ITEM Q'TY REMARKS
Cam chain cover nut 2 6 12 (1.2, 9) U-nut
1-9
dummyhead
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING
THREAD TORQUE
ITEM Q'TY REMARKS
Front axle nut 1 12 59 (6.0, 44) U-nut
Speedometer cable mounting screw 1 5 2 (0.2, 1.5)
Front brake disc socket bolt (Except MX type) 3 8 42 (4.3, 31) ALOC bolt:
replace with
a new one
Handlebar post nut 1 10 49 (5.0, 36) Apply engine
oil to the
threads and
seating
surface.
Fork socket bolt 2 8 20(2.0, 15) Apply locking
agent to the
threads.
Fork cap bolt 2 26 22(2.2, 16)
Fork pinch bolt 4 10 49 (5.0, 36)
Front brake master cylinder holder bolt (Except MX 2 6 12 (1.2, 9)
type)
Steering stem adjusting nut/upper inner race 1 BC1 See page 13-29
Steering stem lock nut 1 BC1 See page 13-29
REAR WHEEL/SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
Rear axle nut 1 16 118 (12.0, 87) U-nut. Apply
engine oil to
the threads
and seating
surface.
BRAKE SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
Front brake Caliper bleed valve 1 8 6 (0.6, 4.4)
(Except MX Master cylinder reservoir cap screw 2 4 2 (0.2, 1.5)
type) Pad pin plug 2 10 3 (0.3, 2.2)
Pad pin 2 10 18 (1.8, 13)
Master cylinder holder bolt 2 6 12 (1.2, 9)
Lever pivot screw 1 6 1 (0.1, 0.7)
Lever pivot nut 1 6 6 (0.6, 4.4)
Light switch screw 2 4 1 (0.1, 0.7)
Caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt:
replace with
a new one
Caliper pin bolt 2 8 18 (1.8, 13)
Hose oil bolt 2 10 34 (3.5, 25)
Rear brake Arm bolt 1 6 10 (1.0, 7) ALOC bolt:
replace with
a new one
Lever pivot screw (MX type) 1 5 1.0 (0.1, 0.7)
Lever pivot nut (MX type) 1 5 4.5 (0.5, 3.3) U-nut
Equalizer rod pivot screw (Except MX 1 5 1.0 (0.1, 0.7)
type)
Equalizer rod pivot nut (Except MX 1 5 4.5 (0.5, 3.3) U-nut
type)
Equalizer connecting cable lock nut 1 8 6.4 (0.7, 4.7)
(Except MX type)
Equalizer bracket cover special screw 1 – 4.2 (0.4, 3.1)
(Except MX type)
Equalizer bracket cover screw 3 – 4.2 (0.4, 3.1)
(Except MX type)
1-10
dummyhead
GENERAL INFORMATION
OTHERS
THREAD TORQUE
ITEM Q'TY REMARKS
Main wire harness clamp screw 1 6 2 (0.2, 1.5) U-nut
Crankcase breather hose holder screw 1 6 2 (0.2, 1.5) U-nut
Sidestand pivot bolt (Except SA type) 1 10 10 (1.0, 7)
Sidestand pivot nut (Except SA type) 1 10 29 (3.0, 22)
Centerstand pivot bolt 1 10 39 (4.0, 29)
LUBRICATION & SEAL POINTS

ENGINE
MATERIAL LOCATION REMARKS
Liquid sealant (Three bond Alternator wire grommet
1207B or 1211 or equivalent)
Locking agent Starter clutch socket bolt

Multi-purpose grease Driven face inner surface 7.0 – 8.0 g
Movable driven face guide groove 2.0 – 2.5 g
Driven face needle bearing
Driven face ball bearing
Kickstarter spindle bearing area
Kickstarter idle gear shaft bushing
Kickstarter idle gear shaft whole surface
Kickstarter idle gear friction spring groove 0.5 g
Kickstarter idle gear friction spring sliding area
Engine oil Oil pump drive and driven gear teeth
Oil pump drive chain whole surface
Oil pump rotor shaft whole surface
Oil pump rotor whole surface
Cylinder stud bolt threads (camshaft holder side)
Camshaft holder nut threads and seating surface
Rocker arm shaft sliding surface
Rocker arm slipper sliding surface
Valve adjusting nut threads and seating surface
Camshaft bearing
Cam sprocket teeth
Cam chain whole surface
Valve stem (valve guide sliding surface)
Valve stem seal inner surface
Piston and cylinder sliding surfaces
Piston pin hole sliding area
Piston ring whole surface and ring grooves
Piston pin outer surface
Connecting rod small end inner surface
Bearing area of drive, counter and final shaft
Drive, counter and final gear teeth
Starter motor idle gear teeth
Starter motor idle gear shaft whole surface
Starter clutch gear teeth
Starter clutch lock nut threads and seating surface
Starter clutch roller sliding area
Left crankshaft thread surface
Crankshaft bearings Fill up 2 cc minimum
(Each bearing)
Connecting rod big end bearing Fill up 3 cc minimum
Each O-ring whole surface
Oil seal lips and outer surfaces
Molybdenum Camshaft cam lobes
disulfide oil (a mixture of 1/2
engine oil and 1/2
molybdenum disulfide
grease)
1-11
dummyhead
GENERAL INFORMATION
Degrease Crankshaft tapered area
Kickstarter driven sprocket tapered area
Flywheel tapered area
Drive/driven pulley face and drive belt
FRAME
Multi-purpose grease with Steering dust seal lip surface
extreme pressure agent Steering bearing race and bearing Fill up 3.0 – 5.0 g to each
(recommended: Shell ALVANIA bearing race
EP2 or EXCELITE EP2
manufactured by KYODO
YUSHI, japan or equivalent)
Multi-purpose grease Front wheel dust seal lip
Speedometer gear box seal surface (Except MX type) 1 – 1.5 g
Speedometer gear and rolling surface 2g
Front brake cam and panel seal lips (MX type)
Front brake panel anchor pin (MX type)
Front brake cam pivot sliding area (MX type)
Rear brake cam and shaft sliding area
Rear brake panel anchor pin
Rear brake lever pivot (MX type)
Seat lock connecting area 1.5 g
Throttle pipe side of throttle cable sliding area
Centerstand pivot
Centerstand stopper rubber bar
Sidestand pivot (Except SA type)
Equalizer sliding area (Except MX type)
Equalizer rod pivot bolt sliding surface (Except MX type)
Rear brake lever pivot screw sliding surface (Except MX
type)
Silicone grease Speedometer cable
Throttle cable inside of boot Fill up 0.1 cc
Throttle cable surface Fill up 0.2 g/m minimum
Front brake lever pivot screw (Except MX type)
Brake master cylinder piston and lever contact area
Brake caliper dust seal lips
Brake caliper bracket pin outer surface Fill up 0.4 g minimum
Brake fluid (DOT 3 or DOT 4) Brake master cylinder piston and cup
Brake caliper piston and seal
Adhesive (Honda bond A or Handlebar grip rubber inside
equivalent) Air cleaner connecting hose-to-housing mating area
Air cleaner element seal surface
Engine oil Rear axle nut threads and seating surface
Handlebar post nut threads
Fork fluid Fork dust seal and oil seal lip
1-12
dummyhead
GENERAL INFORMATION
CABLE & HARNESS ROUTING
EXCEPT MX TYPE:
LEFT HANDLEBAR DIMMER SWITCH

SWITCH WIRE 3P CONNECTOR
REAR BRAKE LIGHT TURN SIGNAL LIGHT

FRONT BRAKE LIGHT SWITCH WIRE SWITCH 3P (Red)
STARTER SWITCH 3P SWITCH WIRE CONNECTORS CONNECTOR
(Black) CONNECTOR CONNECTORS
HORN SWITCH 3P
(Black) CONNECTOR
REAR BRAKE
CABLE
HORN WIRE
CONNECTING CABLE
THROTTLE CABLE
FRONT BRAKE HOSE
METER/HANDLEBAR
SWITCH WIRE
IGNITION SWITCH WIRE
SPEEDOMETER CABLE
RESISTOR WIRE
1-13
dummyhead
GENERAL INFORMATION
SPEEDOMETER CABLE
8 – 12 mm (0.3 – 0.5 in)
REAR BRAKE
CABLE
HORN WIRE
FRONT BRAKE Front THROTTLE
HOSE CABLE
METER/
HANDLEBAR
SWITCH WIRE
METER/HANDLEBAR RESISTOR WIRE

SWITCH WIRE
METER/HANDLEBAR
SWITCH WIRE
FRONT BRAKE HOSE

5 mm (0.2 in)
THROTTLE
MAX
TURN SIGNAL RELAY CABLE
REAR BRAKE
CABLE
Front FRONT BRAKE HOSE
SPEEDOMETER CABLE
2 mm (0.1 in)
RESISTOR THROTTLE CABLE MAX
SPEEDOMETER
CABLE Front
REAR BRAKE
THROTTLE
CABLE
CABLE
REAR BRAKE CABLE
1-14
dummyhead
GENERAL INFORMATION
HANDLEBAR
MASTER
REAR
CYLINDER
HANDLEBAR
COVER
SWITCH COVER
STARTER
SWITCH WIRE
FRONT
BRAKE HOSE
LEFT FRONT TURN

SIGNAL LIGHT WIRE
THROTTLE CABLE
METER/HANDLEBAR HEADLIGHT
SWITCH WIRE WIRE
TURN SIGNAL RELAY

3P CONNECTOR
RIGHT FRONT TURN
SIGNAL LIGHT WIRE
CONNECTORS:
· METER/HANDLEBAR SWITCH 9P
· HEADLIGHT/TURN SIGNAL RELAY/POSITION
LIGHT 9P (Red)
POSITION LIGHT WIRE
· RESISTOR WIRE
· LEFT FRONT TURN SIGNAL LIGHT 2P (Brown)
· RIGHT FRONT TURN SIGNAL LIGHT 2P (Black)
MAIN WIRE HARNESS
SPEEDOMETER CABLE
1-15
dummyhead
GENERAL INFORMATION
MX TYPE:
LEFT HANDLEBAR
SWITCH WIRE
DIMMER SWITCH
3P CONNECTOR
TURN SIGNAL LIGHT

REAR BRAKE LIGHT SWITCH 3P (Red)
FRONT BRAKE LIGHT CONNECTOR
STARTER SWITCH 3P SWITCH WIRE
SWITCH WIRE
(Black) CONNECTOR
CONNECTORS
HORN SWITCH 3P
(Black) CONNECTOR
HORN WIRE
FRONT BRAKE CABLE

REAR BRAKE CABLE
THROTTLE CABLE
SPEEDOMETER CABLE
METER/HANDLEBAR
SWITCH WIRE
IGNITION SWITCH WIRE
RESISTOR WIRE
1-16
dummyhead
GENERAL INFORMATION
SPEEDOMETER CABLE
8 – 12 mm (0.3 – 0.5 in)
REAR BRAKE
CABLE
HORN WIRE
FRONT BRAKE THROTTLE
Front
CABLE CABLE
METER/
HANDLEBAR
SWITCH WIRE
METER/HANDLEBAR RESISTOR WIRE

SWITCH WIRE
METER/HANDLEBAR
SWITCH WIRE
FRONT BRAKE CABLE

5 mm (0.2 in)
THROTTLE
MAX
TURN SIGNAL RELAY CABLE
REAR BRAKE
CABLE
Front FRONT BRAKE CABLE
SPEEDOMETER CABLE
2 mm (0.1 in)
RESISTOR THROTTLE CABLE
MAX
SPEEDOMETER
Front
CABLE
REAR BRAKE
THROTTLE
CABLE
CABLE
REAR BRAKE CABLE
1-17
dummyhead
GENERAL INFORMATION
HANDLEBAR
REAR LEVER
HANDLEBAR BRACKET
COVER
SWITCH COVER
STARTER
SWITCH WIRE
FRONT BRAKE CABLE
LEFT FRONT TURN

SIGNAL LIGHT WIRE
THROTTLE CABLE
METER/HANDLEBAR HEADLIGHT
SWITCH WIRE WIRE
TURN SIGNAL RELAY

3P CONNECTOR
RIGHT FRONT TURN
SIGNAL LIGHT WIRE
CONNECTORS:
· METER/HANDLEBAR SWITCH 9P
· HEADLIGHT/TURN SIGNAL RELAY/POSITION
LIGHT 9P (Red)
POSITION LIGHT WIRE
· RESISTOR WIRE
· LEFT FRONT TURN SIGNAL LIGHT 2P (Brown)
· RIGHT FRONT TURN SIGNAL LIGHT 2P (Black)
MAIN WIRE HARNESS
1-18
dummyhead
GENERAL INFORMATION
ALL TYPES:
MAIN WIRE HARNESS
THROTTLE CABLE
REAR BRAKE CABLE
FLOOR PANEL
STARTER
MOTOR CABLE
STARTER MOTOR
CABLE
STARTER RELAY MAIN WIRE
MAIN FUSE 2P HARNESS
CONNECTOR
BATTERY NEGATIVE
(-) CABLE
IGNITION CONTROL
MODULE (ICM) BATTERY
POSITIVE (+)
TERMINAL
BATTERY
BATTERY
MAIN FUSE
NEGATIVE (-)
SUB FUSE TERMINAL
1-19
dummyhead
GENERAL INFORMATION
STARTER MOTOR CABLE SE THERMAL VALVE WIRE
SE THERMAL VALVE WIRE
ALTERNATOR WIRE
BATTERY NEGATIVE (-) CABLE
MAIN WIRE
HARNESS
FRAME GROUND
FRAME GROUND CABLE CABLE
5 mm (0.2 in)
STARTER MOTOR
MAX
CABLE
BATTERY NEGATIVE FRAME GROUND STARTER MOTOR CABLE

(-) CABLE CABLE
MAIN WIRE HARNESS SE THERMAL VALVE WIRE
ALTERNATOR WIRE
SE THERMAL
VALVE WIRE
5 mm (0.2 in)
SPARK PLUG MAX
WIRE
BATTERY NEGATIVE
(-) CABLE MAIN WIRE
HARNESS
SA TYPE Shown: ALTERNATOR WIRE

FRAME GROUND CONNECTORS:
CABLE · FUEL LEVEL SENSOR 3P
· BRAKE/TAILLIGHT 3P
STARTER MOTOR
· RIGHT REAR TURN SIGNAL 3P (Black)
CABLE
BATTERY NEGATIVE · LEFT REAR TURN SIGNAL 3P (Red)
(-) CABLE · LICENSE LIGHT WIRE (SA TYPE)
LICENSE
LIGHT WIRE
(SA TYPE only)
REGULATOR/
RECTIFIER
THROTTLE CABLE
FUEL TRAY
FUEL HOSE FUEL LEVEL
DRAIN HOSE
FUEL AUTO VALVE/CARBURETOR SENSOR WIRE
AIR CUT-OFF VALVE VACUUM HOSE CRANKCASE
BREATHER HOSE
1-20
dummyhead
GENERAL INFORMATION
FUEL TRAY
DRAIN HOSE SEAT LOCK CABLE
REGULATOR/
RECTIFIER WIRE
FUEL AUTO VALVE

FUEL LEVEL VACUUM HOSE
SENSOR WIRE
FUEL HOSE
THROTTLE CABLE
MAIN WIRE
HARNESS
SPARK PLUG WIRE
CRANKCASE
BREATHER HOSE
IGNITION COIL
PRIMARY WIRE
SE THERMAL
VALVE WIRE
ALTERNATOR
WIRE
CONNECTORS:
· ALTERNATOR/IGNITION PULSE GENERATOR 3P FRAME GROUND
· SE THERMAL VALVE 2P (Red) CABLE REAR BRAKE
CABLE
1-21
dummyhead
GENERAL INFORMATION
MAIN WIRE HARNESS
FUEL HOSE
REGULATOR/RECTIFIER
4P (GREEN) CONNECTOR
FUEL AUTO VALVE

VACUUM HOSE
CONNECTORS:
LICENSE · ALTERNATOR/IGNITION PULSE
LIGHT WIRE GENERATOR 3P
(SA TYPE only) · SE THERMAL VALVE 2P (Red)
SE THERMAL
VALVE WIRE
FRAME
GROUND
CABLE
ALTERNATOR WIRE
IGNITION COIL
1-22
dummyhead
GENERAL INFORMATION
CARBURETOR AIR
CUT-OFF VALVE HOSE FUEL TRAY DRAIN HOSE
CRANKCASE
BREATHER HOSE
REGULATOR/
RECTIFIER 4P (Green)
CONNECTOR
LICENSE
LIGHT WIRE
(SA TYPE only)
FUEL LEVEL
SENSOR WIRE
CRANKCASE BREATHER DRAIN HOSE
CRANKCASE
BREATHER HOSE
THROTTLE CABLE CRANKCASE BREATHER

DRAIN HOSE
REAR BRAKE CABLE
FINAL REDUCTION CASE

BREATHER HOSE
1-23
dummyhead
GENERAL INFORMATION
STARTER GROUND CABLE

MOTOR CABLE
IGNITION COIL
GROUND PRIMARY WIRE STARTER MOTOR CABLE
CABLE ALTERNATOR
SPARK PLUG WIRE
WIRE BATTERY
IGNITION COIL
NEGATIVE (-)
PRIMARY WIRE
CABLE
ALTERNATOR
SPARK PLUG WIRE
WIRE
BATTERY
NEGATIVE (-) IGNITION COIL
CABLE SPARK PLUG PRIMARY WIRE
WIRE
SE THERMAL
VALVE WIRE
FUEL AUTO VALVE

VACUUM HOSE
FUEL HOSE
CRANKCASE BREATHER HOSE
THROTTLE CABLE CARBURETOR DRAIN HOSE
REAR BRAKE CABLE
RIGHT REAR TURN

SIGNAL 3P (Black)
CONNECTOR
BRAKE/TAILLIGHT 3P CONNECTOR
LEFT REAR TURN SIGNAL 3P (Red) CONNECTOR
1-24
dummyhead
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons. Control of oxides of nitrogen and
hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to
sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.
CRANKCASE
BREATHER HOSE
FRESH AIR
BLOW-BY GAS
CARBURETOR
AIR CLEANER HOUSING
1-25
dummyhead
MEMO
dummytext
2. FRAME/BODY PANELS/EXHAUST SYSTEM
BODY PANEL LOCATIONS ·························2-2 UNDER COVER ············································ 2-7
BODY PANEL REMOVAL CHART ···············2-2 FLOOR PANEL ············································· 2-8
SERVICE INFORMATION ·····························2-3 FRONT HANDLEBAR COVER ····················· 2-8
TROUBLESHOOTING···································2-3 REAR HANDLEBAR COVER ······················· 2-9
FLOOR MAT··················································2-4 FRONT COVER············································· 2-9
LUGGAGE BOX ············································2-4 FRONT INNER COVER ······························ 2-11
REAR CARRIER············································2-4 FRONT LOWER COVER ···························· 2-12
REAR CENTER LOWER COVER ·················2-5 FRONT FENDER········································· 2-12
SIDE COVER ·················································2-5 REAR FENDER ··········································· 2-12
CENTER COVER···········································2-5 SEAT ··························································· 2-13
BODY COVER ···············································2-6 MUFFLER···················································· 2-13
2-1
dummyhead

BODY PANEL LOCATIONS
(11) (12)
(2) (17)
(14)
(13)
(7)
(3)
(1)
(16)
(4)
(9)
(15) (5)
(10)
(8) (6)
(1) Floor mat (page 2-4) (7) Body cover (page 2-6) (13) Front cover (page 2-9)
(2) Luggage box (page 2-4) (8) Under cover (page 2-7) (14) Front inner cover (page 2-11)
(3) Rear carrier (page 2-4) (9) Rear fender (page 2-12) (15) Front lower cover (page 2-12)
(4) Rear center lower cover (page 2-5) (10) Floor panel (page 2-8) (16) Front fender (page 2-12)
(5) Side cover (page 2-5) (11) Front handlebar cover (page 2-8) (17) Seat (page 2-13)
(6) Center cover (page 2-5) (12) Rear handlebar cover (page 2-9)
BODY PANEL REMOVAL CHART

• This chart shows removal order of frame covers by means of arrow.
(11) FRONT HANDLEBAR COVER (12) REAR HANDLEBAR COVER (2) LUGGAGE BOX
(1) FLOOR MAT (5) SIDE COVER (8) UNDER COVER (3) REAR CARRIER
(6) CENTER COVER (7) BODY COVER (4) REAR CENTER LOWER COVER
(9) REAR FENDER (10) FLOOR PANEL (13) FRONT COVER (17) SEAT
(16) FRONT FENDER (14) FRONT INNER COVER
(15) FRONT LOWER COVER
2-2
dummyhead

SERVICE INFORMATION
GENERAL
• This section covers removal and installation of the body panels and exhaust system.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine.
• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust joint nut first,
then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• Always inspect the exhaust system for leaks after installation.
TROUBLESHOOTING
Excessive exhaust noise
• Broken exhaust system
• Exhaust gas leak
Poor performance
• Deformed exhaust system
• Exhaust gas leak
• Clogged muffler
2-3
dummyhead

FLOOR MAT
REMOVAL/INSTALLATION
Remove the floor mat by pulling the retaining bosses
BOSSES
out of the holes of the floor panel and front inner cover.
Installation is in the reverse order of removal.
FLOOR MAT
LUGGAGE BOX
Open the seat by ignition key.
SCREW WASHER BOLTS
Remove the screw, five mounting washer bolts and the
luggage box.
LUGGAGE BOX
REAR CARRIER
Remove the luggage box (page 2-4).
Except MX type shown: BOLTS
Remove the three bolts and rear carrier.
REAR CARRIER
2-4
dummyhead

REAR CENTER LOWER COVER
Remove the two screws.
REAR CENTER
Release the tabs of the rear center lower cover from the LOWER COVER
slots of the body cover. TABS
SCREWS
SIDE COVER
Remove the floor mat (page 2-4).
Remove the screw, washer screw and trim clips.
Release the front hooks by slightly sliding the side cover
rearward.
Release the trim clip tabs and rear hooks by sliding the
side cover forward, then remove it.
WASHER SCREW
HOOKS
TRIM CLIPS
SIDE COVER
HOOKS SCREW TABS
CENTER COVER
Remove the floor mat (page 2-4).
CENTER COVER
Remove the screws. SCREWS
Release the front side of the center cover by pulling it

up at the groove and remove the center cover by
releasing the tabs from the slots of the body cover.
TABS
2-5
dummyhead

BODY COVER
Remove the following:
– Rear center lower cover (page 2-5) BODY COVER BOLTS
– Side covers (page 2-5).
– Rear carrier (page 2-4)
– Center cover (page 2-5) SCREWS
– Two bolts the from the rear side
– Two trim clips from the both sides
– Two screws from the front side
Disconnect the seat lock cable from the seat lock HOOKS
bracket.
Slide the body cover rearward to release the hooks CONNECTORS
from the floor panel.
Be careful not to Disconnect the brake/tail light 3P connector and rear
damage the wire. turn signal 3P connectors, then remove the body cover.
TRIM CLIPS
SEAT LOCK CABLE
DISASSEMBLY/ASSEMBLY
Remove the screws.
Left side shown: HOOKS
Release the three hooks and separate the body covers
from the rear center cover. BODY COVER
SCREWS
REAR CENTER COVER
Left side only: Remove the screws and seat lock cover from the left Left side only:
body cover.
SEAT LOCK HOLDER
Disconnect the seat lock cable from the key cylinder CABLE BRACKET SCREWS
and holder bracket.
Remove the spring, holder bracket and key cylinder.
SEAT LOCK COVER
LEFT BODY COVER

SPRING
KEY CYLINDER
2-6
dummyhead

Remove the screws.
BRAKE/TAIL SCREWS
Release the five hooks and remove the brake/tail light LIGHT UNIT
unit from the rear center cover.
HOOKS
REAR CENTER COVER
Left side only: Remove the screws and wire bands.

TURN SIGNAL UNIT
Remove the screws and separate the rear turn signal WIRE BANDS
SCREWS
unit from the brake/tail light unit.
BRAKE/TAIL
Assembly is in the reverse order of disassembly.
LIGHT UNIT
SCREWS
UNDER COVER
Remove the side covers (page 2-5).
HOOK
Remove the three washer bolts and release the bolt
holes from the bosses of the frame.
Remove the under cover by pulling it rearward and
releasing it from the hook on the frame.
WASHER
BOLTS
UNDER COVER
2-7
dummyhead

FLOOR PANEL
Left side shown: FLOOR PANEL B
– Battery (page 16-4)
– Starter relay (page 18-7)
– ICM (page 17-7)
– Body cover (page 2-6)
Remove the floor panel B by releasing the tabs from the
slots.
TABS
Remove the washer bolts and special bolts.

Pull the rear side of floor panel A upward and release
the bosses, then rearward to release the front tabs from SPECIAL BOLTS
the slots.
Remove the floor panel A while pulling the wires out
from the hole. FLOOR PANEL A WIRES
Route the wire Installation is in the reverse order of removal.
harness properly
(page 1-13).
WASHER
BOLTS
HOLE
FRONT
TABS
BOSSES
FRONT HANDLEBAR COVER

Pull up the boots and remove the rear view mirrors.
REAR VIEW MIRROR
BOOT
2-8
dummyhead

FRONT CENTER TAB
– Two screws from the rear side HANDLEBAR
– Two screws from the both sides COVER
Release the upper bosses from the holes and center
tab from the slot, then remove the front handlebar
cover.
BOSSES
SCREWS
REAR HANDLEBAR COVER

Remove the front handlebar cover (page 2-8).
Disconnect the handlebar switch connectors. CONNECTORS
Remove the four rear handlebar cover mounting screws

and three speedometer mounting screws, then remove
the rear handlebar cover.
Route the wire Installation is in the reverse order of removal. SCREWS
harness properly
(page 1-13).
REAR
HANDLEBAR
COVER
FRONT COVER
Remove the lower screw.
Remove the four screws from the rear side. FRONT COVER
Release the hooks and bosses by sliding the front cover SCREWS
forward and lift it up.
Disconnect the headlight 9P (red) connector and front HOOKS
turn signal 2P connectors, then remove the front cover.
CONNECTORS
LOWER SCREW
2-9
dummyhead

Remove the screws and washers.
Release the holes from the screw bosses and remove SCREWS HEADLIGHT/FRONT
the headlight/front turn signal units from the front cover. TURN SIGNAL UNITS
SCREWS/
WASHERS
FRONT COVER
Left side only: Remove the wire band boss from the headlight unit.
Left side shown:
Remove the screws and washers, then separate the HEADLIGHT
front turn signal unit from the headlight unit. UNIT
WIRE
BAND
BOSS
TURN SIGNAL UNIT

SCREWS/WASHERS
2-10
dummyhead

FRONT INNER COVER
– Floor panel (page 2-8)
– Front cover (page 2-9)
– Two screws from the rear side
– Four screws from the front side
– Bolt and luggage hook
Release the handlebar switch/meter wire from the
clamps of the front inner cover.
Remove the front inner cover by releasing the bosses
and holes from the front inner cover.
harness properly
(page 1-13).
LUGGAGE HOOK
FRONT INNER COVER BOLT
CLAMPS
SCREWS
HOLES
BOSSES
2-11
dummyhead

FRONT LOWER COVER
– Side covers (page 2-5)
– Front cover (page 2-9) SCREWS
– Front wheel (page 13-5)
– Front fender (page 2-12)
– Two screws from the rear side
FRONT LOWER
– Four screws from the front side
– Bolts from the front side COVER
Release the bosses of front inner cover and remove the

front lower cover.
Remove the collars.
COLLARS BOSSES
BOLTS
FRONT FENDER
Remove the four special bolts and front fender.
Installation is in the reverse order of removal. FRONT
FENDER
• Replace the bolts with new ones.
BOLTS
REAR FENDER
Remove the body cover (page 2-6).
SA type shown:
MAIN WIRE
SA type only: Disconnect the license light wire connectors. HARNESS
FUEL HOSE/
Release the following from the grooves of the rear VACUUM HOSE
HOOK WIRE
fender:
CONNECTORS
– Fuel hose (SA type only)
– Fuel auto valve vacuum hose
– Main wire harness
– Fuel level sensor wire
Release the bolt holes from the bosses on the frame.
Remove the rear fender by pulling it rearward and
releasing it from the hook of the frame.
harness properly
(page 1-13). FUEL LEVEL GROOVES
SENSOR
WIRE BOSSES REAR BOLT
FENDER HOLES
2-12
dummyhead

SEAT
Open the seat by ignition key.
NUTS
Remove the nuts while supporting the seat, then
remove the seat.
SEAT
MUFFLER
– Exhaust pipe joint nuts
– Muffler mounting bolts
– Muffler and gasket
GASKET
NUTS
MUFFLER MOUNTING BOLTS
2-13
dummyhead

Replace the exhaust pipe gasket with a new one.
Align the exhaust pipe flange with the stud bolts and
install the joint nuts, but do not tighten yet. 1, 2
Install the muffler mounting bolts, but do not tighten yet.
3
Tighten the exhaust pipe joint nuts and muffler
mounting bolts in the sequence as shown.
TORQUE:
EXHAUST PIPE JOINT NUT:
29 N·m (3.0 kgf·m, 22 lbf·ft)
MUFFLER MOUNTING BOLT:
59 N·m (6.0 kgf·m, 44 lbf·ft)
4
After installation, inspect the exhaust system for leaks.
2-14
dummytext
3. MAINTENANCE
SERVICE INFORMATION ·····························3-2 BRAKE FLUID (EXCEPT MX TYPE) ·········· 3-10
MAINTENANCE SCHEDULE························3-2 BRAKE SHOES WEAR

(MX TYPE)··················································· 3-10
FUEL LINE·····················································3-3
BRAKE SHOES/PADS WEAR
THROTTLE OPERATION······························3-3 (EXCEPT MX TYPE) ··································· 3-11
AIR CLEANER···············································3-4 BRAKE SYSTEM ········································ 3-11
CRANKCASE BREATHER ···························3-4 BRAKE LOCK OPERATION ······················ 3-14
SPARK PLUG················································3-5 HEADLIGHT AIM ········································ 3-14
VALVE CLEARANCE····································3-6 CLUTCH SHOES WEAR ···························· 3-15
ENGINE OIL ··················································3-7 SIDESTAND (EXCEPT SA TYPE) ·············· 3-15
ENGINE OIL STRAINER SCREEN ···············3-8 SUSPENSION ············································· 3-15
ENGINE IDLE SPEED ···································3-8 NUTS, BOLTS, FASTENERS ····················· 3-15
DRIVE BELT··················································3-8 WHEELS/TIRES ·········································· 3-16
FINAL DRIVE OIL··········································3-9 STEERING HEAD BEARINGS ··················· 3-16
3-1
dummyhead
MAINTENANCE
SERVICE INFORMATION
MAINTENANCE
GENERAL
• Place the scooter on a level ground before starting any work.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the
engine in an open area or with an exhaust evacuation system in an enclosed area.
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult a dealer.
FREQUENCY (NOTE 1) REFER
ANNUAL
ITEMS NOTE X 1,000 km 1 4 8 12 16 20 24 TO
CHECK
X 1,000 mi 0.6 2.5 5 7.5 10 12.5 15 PAGE
*FUEL LINE I I I I I I I 3-3
*THROTTLE OPERATION I I I I I I I 3-3
*AIR CLEANER NOTE 2 R 3-4
CRANKCASE BREATHER NOTE 3 C C C C C C C 3-4
SPARK PLUG I R I R I R 3-5
* VALVE CLEARANCE I I I I I I I 3-6
ENGINE OIL R R R R R R R R 3-7
ENGINE OIL STRAINER C C 3-8
SCREEN
* ENGINE IDLE SPEED I I I I I I I I 3-8
* DRIVE BELT I I R 3-8
* FINAL DRIVE OIL NOTE 4 3-9
BRAKE FLUID NOTE 4 I I I I I I I 3-10
(EXCEPT MX TYPE)
BRAKE SHOES WEAR I I I I I I I 3-10
(MX TYPE)
BRAKE SHOES /PADS I I I I I I I 3-11
WEAR (EXCEPT MX
TYPE)
BRAKE SYSTEM I I I I I I I I 3-11
* BRAKE LOCK I I I I I I I 3-14
OPERATION
HEADLIGHT AIM I I I I I I I 3-14
** CLUTCH SHOES WEAR I I I 3-15
SIDESTAND I I I I I I I 3-15
(EXCEPT SA TYPE)
* SUSPENSION I I I I I I I 3-15
* NUTS, BOLTS, I I I I I 3-15
FASTENERS
** WHEELS/TIRES I I I I I I I 3-16
** STEERING HEAD I I I I 3-16
BEARINGS
*SHOULD BE SERVICED BY A DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS
MECHANICALLY QUALIFIED.
** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY A DEALER.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replace every 2 years. Replacement requires mechanical skill.
3-2
dummyhead
MAINTENANCE
FUEL LINE
FUEL HOSE
Check the fuel hose for deterioration, damage or
leakage.
Replace the fuel hose if necessary.
Also, check the fuel hose fittings for leakage.
Install the luggage box (page 2-4).
THROTTLE OPERATION
Reusing an Check for any deterioration or damage to the throttle
abnormally bent or cable.
kinked throttle cable Check the throttle grip for smooth operation.
can prevent proper Check that the throttle opens and automatically closes 2 – 6 mm (0.1 – 0.2 in)
throttle slide in all steering positions.
operation.
If the throttle grip does not return properly, overhaul and
lubricate the throttle grip housing.
If the throttle grip still does not return properly, replace
the throttle cable.
With the engine idling, turn the handlebar all the way to
the right and left to ensure that the idle speed does not
change. If idle speed increases, check the throttle grip
freeplay and throttle cable connection.
Measure the throttle grip freeplay at the throttle grip
flange.
FREEPLAY: 2 – 6 mm (0.1 – 0.2 in)
Throttle grip freeplay can be adjusted by turning the
BOOT LOCK NUT
adjuster.
Pull off the boot from the adjuster.
Loosen the lock nut and turn the adjuster as required.
Tighten the lock nut and put the boot back in the
appropriate position.
ADJUSTER
3-3
dummyhead
MAINTENANCE
AIR CLEANER
• The viscous paper element cannot be cleaned
because the element contains a dust adhesive.
• If the scooter is used in unusually wet or dusty
areas, more frequent inspections are required.
Remove the left side cover (page 2-6).
AIR CLEANER
Remove the screws and air cleaner housing cover. HOUSING COVER
SCREWS
Remove the screw and air cleaner element.

SCREW
Remove and discard the air cleaner element in
accordance with the maintenance schedule (page 3-2).
Replace the element any time if it is excessively dirty or
damaged.
Install the removed parts in the reverse order of
removal.
TORQUE: AIR CLEANER HOUSING COVER SCREW
1.1 N·m (0.1 kgf·m, 0.7 lbf·ft)
AIR CLEANER ELEMENT SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
AIR CLEANER ELEMENT
CRANKCASE BREATHER
• Service more frequently when ridden in rain, at full
throttle, or after the scooter is washed or overturned.
Service if the deposit level can be seen in the
transparent section of the drain hose.
Remove the crankcase breather drain hose plug from
the hose end and drain deposits into a suitable CRANKCASE BREATHER
container. DRAIN HOSE
Install the crankcase breather drain hose plug.
DRAIN HOSE PLUG
3-4
dummyhead
MAINTENANCE
Check the crankcase breather hose for deterioration,
damage or leakage.
Replace the crankcase breather hose if necessary.
Also check the crankcase breather hose fittings for
leakage.
Install the luggage box (page 2-4).
CRANKCASE BREATHER HOSE
SPARK PLUG
Remove the center cover (page 2-5).
SPARK PLUG CAP
Clean around the Disconnect the spark plug cap and remove the spark
spark plug base plug.
with compressed air
before removing the
spark plug, and
make sure that no
debris is allowed to
enter the
combustion
chamber.
SPARK PLUG
Inspect or replace the spark plug as described in the

maintenance schedule (page 3-2).
Check the following and replace if necessary. CENTER ELECTRODE
• Insulator for damage
• Electrodes for wear
• Burning condition, coloration;
– Dark to light brown indicates good condition.
– Excessive lightness indicates malfunctioning
ignition system or lean mixture.
– Wet or black sooty deposit indicates over-rich
mixture.
INSULATOR
If the electrode is contaminated with carbon deposits,
clean the electrode using a spark plug cleaner. SIDE ELECTRODE
Always use the specified spark plug on this scooter.
SPECIFIED SPARK PLUG:
Standard: CR7HSA (NGK)
Optional: CR6HSA (NGK)
Measure the spark plug gap between the center and
side electrodes with a feeler gauge of a wire type.
If necessary, adjust the gap by bending the side 0.60 – 0.70 mm
electrode carefully. (0.024 – 0.028 in)
SPARK PLUG GAP: 0.60 – 0.70 mm (0.024 – 0.028 in)

Install and hand tighten the spark plug to the cylinder
head, then tighten the spark plug to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Connect the spark plug cap.
Install the center cover (page 2-5).
3-5
dummyhead
MAINTENANCE
VALVE CLEARANCE
• Inspect and adjust the valve clearance while the
engine is cold (below 35°C/95°F).
INSPECTION
– Hole cap INDEX NOTCH HOLE CAP
– Cylinder head cover (page 7-4)
Rotate the crankshaft clockwise and align the "T" mark
on the flywheel with the index notch.
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
This position can be confirmed by checking that there is
slack in the rocker arm.
If there is no slack, it is because the piston is moving
through the exhaust stroke to TDC.
Rotate the crankshaft one full turn and match up the "T"
mark again. "T" MARK
Check the clearance of each valve by inserting a feeler

gauge between the adjusting screw and valve stem. FEELER GAUGE ROCKER ARM
VALVE CLEARANCE:
IN/EX: 0.14 mm (0.006 in)
ADJUSTMENT
If the valve clearance is incorrect, loosen the valve
adjusting screw lock nut and adjust the valve clearance LOCK NUT
by turning the adjusting screw until there is a slight drag
on the feeler gauge.
Hold the adjusting screw and tighten the lock nut to the
specified torque.
ADJUSTING
TOOL:
WRENCH
Valve adjusting wrench 07908-KE90000

After tightening the lock nut, recheck the valve
clearance. ADJUSTING
SCREW
removal.
3-6
dummyhead
MAINTENANCE
ENGINE OIL
OIL LEVEL CHECK
Support the scooter with its centerstand on a level
OIL FILLER CAP/DIPSTICK
surface.
Start the engine and let it idle for 3 - 5 minutes.
Stop the engine and wait for 2 - 3 minutes. UPPER
Remove the oil filler cap/dipstick and wipe off the oil LEVEL
from the dipstick with a clean cloth. LOWER
LEVEL
Insert the oil filler cap/dipstick without screwing it in,
remove it and check the oil level.
The level should be between the "UPPER" and
"LOWER" level lines of the oil filler cap/dipstick.
If the oil level is below or near the lower level line on the
dipstick, add the recommended oil to the upper level.
RECOMMENDED ENGINE OIL:
Honda 4-stroke oil or equivalent motor oil
Make sure the O-ring is in good condition and replace it
if necessary.
Coat the O-ring with engine oil and install the oil filler
cap/dipstick
For engine oil change, See page 3-7.
OIL CHANGE
Support the scooter with its centerstand.
Start the engine, warm it up and stop it.
Remove the oil filler cap/dipstick.
Place an oil drain pan under the engine to collect the oil,
then remove the engine oil drain plug and O-ring.
After draining the oil completely, coat a new O-ring with
clean engine oil and install it to the drain plug.
Install and tighten the drain plug to the specified torque.
Fill the crankcase with recommended engine oil.
O-RING/DRAIN PLUG
RECOMMENDED ENGINE OIL:
ENGINE OIL CAPACITY:

0.9 liter (1.0 US qt, 0.8 Imp qt) after draining
1.0 liter (1.1 US qt, 0.9 Imp qt) after disassembly
Check the engine oil level (page 3-7).
Make sure that there are no oil leaks.
3-7
dummyhead
MAINTENANCE
ENGINE OIL STRAINER SCREEN
Drain the engine oil (page 3-7).
OIL STRAINER SCREEN SPRING
Remove the oil drain plug, O-ring, spring and oil strainer
screen.
Check the oil strainer screen for clogs or damage.
Install the oil strainer screen and spring into the
crankcase as shown.
Coat a new O-ring with clean engine oil and install it to
the drain plug.
Install and tighten the drain plug to the specified torque.
O-RING DRAIN PLUG
Fill the crankcase with recommended engine oil (page
3-7).
Check the engine oil level (page 3-7).
Make sure that there are no oil leaks.
ENGINE IDLE SPEED

• Inspect and adjust the idle speed after all other
engine maintenance items have been performed
and are within specifications.
• The engine must be warm for accurate idle speed
inspection and adjustment. Ten minutes of stop-and-
go riding is sufficient.
Warm up the engine. ADJUSTING HOLE CAP
Connect a tachometer and check the idle speed.
IDLE SPEED:1,700 ± 100 min–1(rpm)
If adjustment is necessary, open the seat by the ignition
key.
Remove the adjusting hole cap.
Adjust the engine idle speed by turning the throttle stop
screw as required.
removal. THROTTLE STOP SCREW
DRIVE BELT
Remove the left crankcase cover (page 9-4).
DRIVE BELT
Check the drive belt for cracks, separation or abnormal
or excessive wear and replace it if necessary (page 9-
7).
3-8
dummyhead
MAINTENANCE
Using the suitable two flat plates, measure the drive belt
width as shown. DRIVE BELT
SERVICE LIMIT:19 mm (0.75 in)

Replace the drive belt if it is less than the service limit
(page 9-7).
FINAL DRIVE OIL

OIL LEVEL CHECK
Make sure that the final reduction case has no oil leaks.
SEALING WASHER
Start the engine and let it idle for a few minutes.
Stop the engine and remove the oil check bolt.
Check whether the oil flows out from the check bolt
hole.
If the level is low (oil does not flow out), add the
recommended oil as described below.
RECOMMENDED FINAL REDUCTION OIL:
JASO T 903 standard: MB CHECK BOLT
LOWER LEVEL
Install the oil check bolt with a new sealing washer and
tighten it to the specified torque.
OIL CHANGE
Place an oil drain pan under the final reduction case to
collect the oil, then remove the oil drain bolt and sealing CHECK BOLT/ SEALING WASHER
washer.
After draining the oil completely, install the new sealing
washer and oil drain bolt.
Tighten the drain bolt to the specified torque.
Fill the final reduction case with recommended oil up to
the correct level (page 3-9).
FINAL REDUCTION OIL CAPACITY:
0.19 liter (0.20 US qt, 0.17 lmp qt) at draining DRAIN BOLT/ SEALING WASHER
0.20 liter (0.21 US qt, 0.18 lmp qt) at disassembly
Install the oil check bolt with a new sealing washer and
3-9
dummyhead
MAINTENANCE
BRAKE FLUID (EXCEPT MX TYPE)
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system
when filling the reservoir.
• Spilling fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
• When the fluid level is low, check the brake pads for
wear (page 3-11).
• A low fluid level may be due to wear of the brake
pads. If the brake pads are worn, the caliper piston is
pushed out, and this accounts for a low reservoir
level. If the brake pads are not worn and the fluid
level is low, check entire system for leaks (page 3-
11).
Place the scooter on a level surface and support it
upright with centerstand.
Turn the handlebar to the left so the reservoir is level
and check the front brake reservoir fluid level through
the sight glass.
If the level is near the lower level line, check the brake
pads for wear (page 3-11).
"LOWER" LEVEL LINE
BRAKE SHOES WEAR

(MX TYPE)
FRONT BRAKE
Check the wear indicator position when the brake lever
is applied. INDEX MARK WEAR INDICATOR
If the indicator aligns with the index mark, inspect the
brake drum (page 15-23).
Replace the brake shoes (page 15-21) if the drum I.D.
is within service limit.
REAR BRAKE
Check the wear indicator position when the brake lever
is applied. INDEX MARK
WEAR INDICATOR
3-10
dummyhead
MAINTENANCE
BRAKE SHOES/PADS WEAR
(EXCEPT MX TYPE)
FRONT BRAKE
Check the brake pads for wear.
LIMIT GROOVES
Replace the brake pads if either pad is worn to the wear
limit groove.
Always replace the Refer to page 15-6 for brake pad replacement.
brake pads as a set
to assure even disc
pressure.
REAR BRAKE
Check the wear indicator position when the brake lever INDEX MARK
is applied.
WEAR INDICATOR
BRAKE SYSTEM
FRONT BRAKE
EXCEPT MX TYPE
Firmly apply the brake lever and check that no air has
entered the system.
If the lever feels soft or spongy when operated, bleed
the air from the system.
Refer to page 15-4 for air bleeding procedures.
Inspect the brake hose and fittings for deterioration,
cracks, or signs of leakage.
Tighten any loose fittings.
Replace hose and fittings as required.
BRAKE HOSE
3-11
dummyhead
MAINTENANCE
MX TYPE
Check the brake cable and brake lever for loose
connections, excessive play or other damage.
Replace or repair if necessary. 10 – 20 mm
Inspect the brake cable for kinks or damage, and (0.4 – 0.8 in)
lubricate the cable.
Measure the front brake lever freeplay at the end of the
lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
Make sure the Adjust the front brake lever freeplay by turning the
cutout on the adjusting nut. ADJUSTING NUT
adjusting nut is
seated on the joint
pin.
REAR BRAKE
• Check the brake lock operation (page 3-14) after the
rear brake lever freeplay is checked and adjusted.
MX TYPE
Check the brake cable and brake lever for loose
connections, excessive play or other damage.
Replace or repair if necessary. 10 – 20 mm
(0.4 – 0.8 in)
Inspect the brake cable for kinks or damage, and
lubricate the cable.
Measure the rear brake lever freeplay at the end of the
lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
Make sure the Adjust the rear brake lever freeplay by turning the rear
cutout on the brake adjusting nut. ADJUSTING NUT
adjusting nut is
seated on the joint
pin.
3-12
dummyhead
MAINTENANCE
EXCEPT MX TYPE
• Before inspection, check the following first:
– Rear brake system (page 3-12)
– Front brake system (page 3-11)
Apply the rear brake lever.
Make sure that the rear wheel does not rotate while the
rear brake lever is applied.
Lift the front wheel off the ground and rotate it by hand.
Make sure that the front wheel rotates smoothly.
Lift the front wheel off the ground and apply the rear
brake lever.
Make sure that the front wheel does not rotate while the
rear brake lever is applied.
If it is abnormal, inspect as follows:
Inspection point
Measure the distance between the edge surface of the
knocker and the edge surface of the master cylinder
body with the feeler gauge.
ADJUSTER
STANDARD: 0 – 0.1 mm (0 – 0.004 in)
If the distance exceeds the standard, adjust the
connecting cable as follows:
Loosen the lock nut and turn the adjuster until the
distance between the edge surfaces is within standard.
KNOCKER LOCK NUT
Check that there is no gap between the knocker pin and

the end of the slot of the knocker joint. KNOCKER PIN
If there is any gap, loosen the lock nut and turn the
adjuster until there is no gap between the knocker pin
and the end of the slot of the knocker joint.
ADJUSTER
After the adjustment, hold the adjuster and tighten the
lock nut to the specified torque.
TORQUE: 6.4 N·m (0.7 kgf·m, 4.7 lbf·ft)
After tightening the lock nut, check that there is no gap
between the knocker pin and the end of the slot of the
knocker joint.
Apply rear brake lever several times and check that the KNOCKER JOINT LOCK NUT
distance between the edges has not been changed
after applying the brake.
Recheck that the distance between the edge surface of
the knocker and the edge surface of the master cylinder Inspection point
body is within standard.
STANDARD: 0 – 0.1 mm (0 – 0.004 in)
Recheck the combined brake system (page 3-13).
If the combined brake system adjustment is normal, but
the front wheel rotates abnormally, check for other
malfunction parts.
Install the front handlebar cover (page 2-8).
KNOCKER
3-13
dummyhead
MAINTENANCE
BRAKE LOCK OPERATION
MX TYPE
Check the brake Squeeze the rear brake lever and set the lock lever.
lock operation after LOCK LEVER
Check that the rear wheel is locked completely.
the rear brake lever
freeplay is checked
and adjusted (page
3-12).
EXCEPT MX TYPE
Check the brake Squeeze the rear brake lever and set the lock lever by
lock operation after pulling it up. LOCK LEVER
the rear brake lever
freeplay is checked Check that the rear wheel is locked completely.
and adjusted (page
3-12).
HEADLIGHT AIM
Adjust the headlight Place the scooter on a level ground.
beam as specified ADJUSTING
Open the glove box.
by local laws and PINION
regulations. Adjust the headlight beam vertically by turning the
headlight aim adjusting pinion.
GLOVE BOX
3-14
dummyhead
MAINTENANCE
CLUTCH SHOES WEAR
Remove the clutch assembly (page 9-11).
Check the clutch shoes for wear or damage.
Measure the thickness of each shoe.
SERVICE LIMIT: 2.0 mm (0.08 in)
Replace the clutch shoes if it is below a service limit
(page 9-12).
removal. 2.0 mm (0.08 in)
CLUTCH SHOE
SIDESTAND (EXCEPT SA TYPE)

SPRING
Check the sidestand spring for damage or loss of
tension.
Check the sidestand assembly for freedom of
movement and lubricate the sidestand pivot if
necessary.
SIDESTAND
SUSPENSION
FRONT
Check the action of the forks by operating the front brake and compressing the front suspension several times.
Check the entire assembly for signs of leaks, damage or loose fasteners.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.
Refer to page 13-14 for fork service.
REAR
Check the action of the rear shock absorber by compressing it several times.
Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.
Refer to page 14-5 for shock absorber service.
Check for worn mounting bushings by grabbing the engine and attempting to move it side to side.
Replace the bushings if any looseness is noted (page 6-9).
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-7).
Check that all cotter pins, safety clips, hose clamps and cable stays are in place and properly secured.
3-15
dummyhead
MAINTENANCE
WHEELS/TIRES
Making sure that the fork is not allowed to move, raise the front wheel and check for play.
Check for worn front wheel bearings by grabbing the front wheel and attempting to move the wheel side to side.
Replace the front wheel bearings if any looseness is noted (page 13-9).
Turn the wheel and check that it rotates smoothly with no unusual noises.
If any abnormal conditions are suspected, inspect the front wheel bearings (page 13-13).
Support the scooter securely and raise the rear wheel.
Check for worn final gear shaft bearings by grabbing the rear wheel and attempting to move the wheel side to
side.
Replace the final gear shaft bearings if any looseness is noted (page 10-7).
Turn the wheel and check that it rotates smoothly with no unusual noises.
If any abnormal conditions are suspected, check the final reduction (page 10-5).
Check the tire pressure with the air pressure gauge when the tires are cold.
RECOMMENDED TIRE PRESSURE:
Driver only:
FRONT: 175 kPa (1.75 kgf/cm2, 25 psi)
REAR: 200 kPa (2.00 kgf/cm2, 29 psi)
Driver and passenger:
FRONT: 175 kPa (1.75 kgf/cm2, 25 psi)
REAR: 225 kPa (2.25 kgf/cm2, 33 psi)
Check the tires for cuts, embedded nails, or other damage.
Check the front wheel and rear wheel for trueness.
RECOMMENDED TIRE SIZE AND TIRE BRAND:
FRONT REAR
Tire size 90/90 – 12 44J 100/90 – 10 56J
Tire CHENG
C – 922F C – 922
brand SHIN
Check the tread depth at the center of the tires.

Replace the tires when the tread depth reaches the following limit.
MINIMUM TREAD DEPTH:
FRONT/REAR: To the indicator
STEERING HEAD BEARINGS

Support the scooter with its centerstand and raise the front wheel off the ground.
Check that the handlebar moves freely from side-to-side.
If the handlebar moves unevenly or binds, inspect the steering head bearings (page 13-27).
Hold the scooter and check the steering head bearings for wear by moving the fork forward and backward.
If the steering stem has vertical movement, inspect the steering head bearings (page 13-27).
3-16
dummytext
4. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM ············4-2 OIL PUMP DRIVE CHAIN ····························· 4-4
SERVICE INFORMATION ·····························4-3 OIL PUMP ····················································· 4-4
TROUBLESHOOTING···································4-3
4-1
dummyhead
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM
INTAKE ROCKER ARM SHAFT
CRANKSHAFT
OIL PUMP
OIL STRAINER SCREEN
4-2
dummyhead
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
• After the oil pump has been installed, check that there are no oil leaks.
TROUBLESHOOTING
Engine oil level too low
• Oil consumption
• External oil leak
• Worn piston rings or incorrect piston ring installation (page 8-6)
• Worn cylinder (page 8-4)
• Worn valve guide or seal (page 7-12)
Oil contamination
• Oil not changed often enough
• Faulty cylinder head gasket
• Worn piston rings (page 8-8)
4-3
dummyhead
LUBRICATION SYSTEM
OIL PUMP DRIVE CHAIN
REMOVAL
Remove the starter clutch (page 11-9).
Remove the snap ring. DRIVE SPROCKET DRIVE CHAIN
Remove the drive sprocket, oil pump drive chain and
driven sprocket as assembly.
INSTALLATION
Apply clean engine oil to the oil pump drive chain and
driven sprocket teeth.
Install the drive sprocket, oil pump drive chain and
driven sprocket as assembly by aligning the driven
sprocket cut-out with the oil pump rotor shaft cut-out.
Install the snap ring.
DRIVEN SPROCKET SNAP RING
Install the starter clutch (page 11-9).
Align
OIL PUMP
• When removing the oil pump, do not allow dust or
dirt to enter the engine.
Drain the engine oil (page 3-7).
Remove the oil pump drive chain (page 4-4). OIL PUMP
Remove the two mounting bolts and the oil pump body
assembly.
After installation, fill the crankcase with recommended
engine oil (page 3-7).
BOLTS
4-4
dummyhead
LUBRICATION SYSTEM
DISASSEMBLY
– Rotor shaft
– Oil pump plate screw
– Oil pump plate
– Pin
– Inner rotor
– Outer rotor
OUTER ROTOR
OIL PUMP PLATE
ROTOR SHAFT
OIL PUMP BODY

SCREW
PIN
INNER ROTOR
ASSEMBLY
Apply engine oil to the inner rotor and outer rotor.
Install them onto the oil pump body. OUTER INNER
ROTOR ROTOR
Install the pin into the oil pump body.
Install the oil pump plate to the oil pump body by
aligning the pin on the oil pump body with the hole of
the oil pump plate. PUMP
PLATE
PUMP
BODY PIN HOLE
4-5
dummyhead
LUBRICATION SYSTEM
Install and tighten the oil pump plate screw to the
specified torque. SCREW
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Coat the rotor shaft with engine oil.

Align
Install the rotor shaft into the oil pump by aligning the
cut-outs of the rotor and oil pump inner rotor.
ROTOR SHAFT
INSPECTION
• Measure at several points and use the largest
reading to compare the service limit.
• If any portion of the oil pump is worn beyond the
specified service limits, replace the oil pump and oil
pump cover as an assembly.
TIP CLEARANCE
Temporarily install the outer, inner rotors and oil pump
ROTOR SHAFT GAUGE
rotor shaft into the oil pump body.
Measure the clearance between the outer rotor and the
inner rotor with a feeler gauge.
INNER
ROTOR
OUTER ROTOR PUMP BODY
4-6
dummyhead
LUBRICATION SYSTEM
BODY CLEARANCE
Measure the clearance between the oil pump body and
the outer rotor with a feeler gauge. PUMP BODY
OUTER ROTOR GAUGE
SIDE CLEARANCE
Measure the side clearance using a straight edge and
feeler gauge. STRAIGHT EDGE
GAUGE
4-7
dummyhead
MEMO
dummytext
5. FUEL SYSTEM
COMPONENT LOCATION ····························5-2 CARBURETOR ASSEMBLY ······················ 5-13
SERVICE INFORMATION ·····························5-2 CARBURETOR CLEANING ······················· 5-19
TROUBLESHOOTING···································5-3 CARBURETOR INSPECTION ···················· 5-19
AIR CLEANER HOUSING·····························5-4 PILOT SCREW ADJUSTMENT ·················· 5-22
CARBURETOR REMOVAL/ INLET PIPE ················································· 5-23

INSTALLATION·············································5-6
FUEL TANK ················································ 5-23
CARBURETOR DISASSEMBLY···················5-8
FUEL AUTO VALVE ··································· 5-24
5-1
dummyhead
FUEL SYSTEM
COMPONENT LOCATION
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
• Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of
vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
• When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
• Before disassembling the carburetor, place a suitable container under the carburetor drain hose. Loosen the drain screw and
drain the carburetor.
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to prevent any
foreign material from dropping into the engine.
5-2
dummyhead
FUEL SYSTEM
TROUBLESHOOTING
Engine won’t start
• No fuel in tank
• No fuel to carburetor
– Fuel strainer clogged
– Fuel hose clogged
– Fuel tank breather hole clogged
– Fuel auto valve stuck
– Fuel auto valve vacuum hose clogged
• Float level misadjusted
• Too much fuel getting to the engine
– Air cleaner clogged
– Flooded carburetor
• Intake air leak
• Fuel contaminated/deteriorated
• Faulty starting enrichment (SE) thermal valve
• Clogged starting enrichment (SE) thermal valve circuit
• Clogged carburetor slow circuit
• Improper throttle operation
Engine stall, hard to start, rough idling
• Fuel line restricted
• Fuel mixture too lean/rich
• Fuel contaminated/deteriorated
• Intake air leak
• Idle speed misadjusted
• Pilot screw misadjusted
• Fuel tank breather hole clogged
• Air cleaner clogged
• Clogged carburetor slow circuit
• Clogged starting enrichment (SE) thermal valve circuit
• Faulty starting enrichment (SE) thermal valve
Lean mixture
• Fuel jets clogged
• Float valve faulty
• Float level too low
• Fuel line restricted
• Carburetor air vent hose clogged
• Blocked fuel tank cap air vent hole
• Intake air leak
• Vacuum piston faulty
Rich mixture
• Air jet clogged
• Float valve faulty
• Float level too high
• Starting enrichment (SE) thermal valve stuck open
• Air cleaner element contaminated
• Vacuum piston faulty
Backfiring or misfiring during acceleration
• Fuel mixture too lean
Afterburn when engine braking is used
• Lean mixture in slow circuit
• Air cut-off valve malfunction
5-3
dummyhead
FUEL SYSTEM
AIR CLEANER HOUSING
REMOVAL
– Left side cover (page 2-5)
– Luggage box (page 2-4)
Loosen the air cleaner connecting hose band screw.
BAND SCREW
Disconnect the crankcase breather hose from the air

cleaner housing. CRANKCASE
BREATHER HOSE
Remove the air cleaner housing mounting bolts.
MOUNTING BOLTS
Be careful not to Disconnect the connecting hose from the carburetor.

damage the
Remove the air cleaner housing by releasing the
connecting hose-to- CRANKCASE
crankcase breather drain hose from the guide.
housing mating BREATHER
area. DRAIN HOSE
INSTALLATION
Set the air cleaner housing in position.
Secure the crankcase breather drain hose with the
guide.
GUIDE
5-4
dummyhead
FUEL SYSTEM
Connect the connecting hose to the carburetor by
aligning the tabs of the air cleaner connecting hose and Align
tab of the carburetor.
Tighten the connecting hose band screw until the band

seats on the collar.
BAND SCREW COLLAR
Install and tighten the air cleaner housing mounting

bolts.
MOUNTING BOLTS
Connect the crankcase breather hose to the air cleaner

housing. CRANKCASE
BREATHER HOSE
Install the following:
5-5
dummyhead
FUEL SYSTEM
CARBURETOR REMOVAL/
INSTALLATION
REMOVAL
Place a suitable container under the carburetor drain
hose and drain fuel from the carburetor by loosening
the drain screw.
Tighten the drain screw to the specified torque.
DRAIN SCREW
Release the carburetor drain hose from the guide.
DRAIN HOSE
GUIDE
Wipe off the spilled Disconnect the fuel hose from the carburetor.
out fuel. SE THERMAL VALVE 2P
Disconnect the air cut-off valve vacuum hose from the (Red) CONNECTOR SE THERMAL
joint and release it from the inlet pipe band clamp. VALVE WIRE
Disconnect the SE thermal valve 2P (Red) connector. WIRE BAND
Release the SE thermal valve wire from the wire bands.
Release the wire band from the frame hole.
WIRE
BANDS FUEL HOSE
VACUUM
JOINT CLAMP HOSE
5-6
dummyhead
FUEL SYSTEM
Loosen the throttle cable lock nut and release the
throttle cable from the cable holder. CABLE HOLDER THROTTLE
Disconnect the throttle cable end from the throttle drum. DRUM
LOCK NUT CABLE END
Loosen the connecting hose band screw and inlet pipe

band screw. Align
Be careful not to Remove the carburetor.

damage the
connecting hose-to-
housing mating INSTALLATION
area.
Connect the carburetor to the connecting hose by
aligning the tab of the carburetor and the tabs of the
connecting hose.
Set the connecting hose band as shown.
Connect the carburetor to the inlet pipe by aligning the
CONNECTING HOSE
tab of the carburetor and the tabs of the inlet pipe.
BAND SCREW
Set the inlet pipe band by aligning the tabs of the band COLLAR
and the tab of the inlet pipe.
Tighten the connecting hose band screw and inlet pipe INLET PIPE Align
band screw until the bands seat on the collars. BAND SCREW
Align
COLLAR
Connect the throttle cable end to the throttle drum and

install the throttle cable to the cable holder. THROTTLE
Tighten the throttle cable lock nut. DRUM
CABLE HOLDER LOCK NUT CABLE END
5-7
dummyhead
FUEL SYSTEM
Set the SE thermal valve wire to the wire bands.
Secure the wire band into the frame hole.
Connect the SE thermal valve 2P (Red) connector. SE THERMAL VALVE 2P
(Red) CONNECTOR SE THERMAL
Connect the air cut-off valve vacuum hose to the joint VALVE WIRE
and secure it with the inlet pipe band clamp.
Connect the fuel hose to the carburetor. WIRE BAND
WIRE
BANDS FUEL HOSE
VACUUM
JOINT CLAMP HOSE
Set the carburetor drain hose to the guide.

After installing the carburetor, check the following:
DRAIN HOSE
– Engine idle speed (page 3-8)
– Throttle grip freeplay (page 3-3)
Install the body cover (page 2-6).
GUIDE
CARBURETOR DISASSEMBLY
HOSES
Disconnect the air cut-off valve vacuum hose and CLAMP VACUUM HOSE
carburetor drain hose.
Release the vacuum hose from the clamp.
DRAIN HOSE
5-8
dummyhead
FUEL SYSTEM
STARTING ENRICHMENT (SE)
THERMAL VALVE
Release the SE thermal valve wire from the wire clamp.
SE THERMAL WIRE CLAMP
Remove the SE thermal valve cover. VALVE COVER
Remove the screws, set plate and SE thermal valve.

SCREWS SE THERMAL
VALVE
SET PLATE
Remove the O-ring from the SE thermal valve.

O-RING SE THERMAL
VALVE
Remove the screws and SE thermal valve body.

SE THERMAL
VALVE BODY
SCREWS
5-9
dummyhead
FUEL SYSTEM
Remove the O-ring from the carburetor body.
O-RING
AIR CUT-OFF VALVE

Remove the screws and throttle cable holder.
THROTTLE CABLE
HOLDER
SCREWS
The air cut-off valve Hold the air cut-off valve cover and remove the screws.
AIR CUT-OFF
cover is under
VALVE COVER
spring pressure.
SCREWS
Remove the cut-off valve cover, spring and diaphragm.

DIAPHRAGM SPRING
AIR CUT-OFF
VALVE COVER
5-10
dummyhead
FUEL SYSTEM
VACUUM CHAMBER
The vacuum Hold the vacuum chamber cover and remove the
WIRE CLAMP
chamber cover is screws, hose clamp and wire clamp.
under spring
pressure.
HOSE CLAMP SCREWS
Remove the vacuum chamber cover, compression

spring and diaphragm/vacuum piston. VACUUM
CHAMBER
COVER
SPRING
DIAPHRAGM/
VACUUM PISTON
Be careful not to Turn the needle holder counterclockwise while pressing

damage the it in and release the holder flanges from the piston JET NEEDLE SPRING
diaphragm. grooves.
Remove the needle holder, spring and jet needle from
the diaphragm/vacuum piston.
DIAPHRAGM/
VACUUM PISTON NEEDLE HOLDER
FLOAT CHAMBER
Remove the screws and float chamber.
SCREWS FLOAT
Remove the O-ring from the float chamber. CHAMBER
O-RING
5-11
dummyhead
FUEL SYSTEM
Be careful not to Hold the carburetor and drive the float pin out from the
damage the throttle drum side gently.
carburetor body.
TOOL:
Pin driver, 4.5 mm 07744-0010400
PIN DRIVER
Remove the float pin, float and float valve.

FLOAT VALVE
FLOAT PIN FLOAT
Handle the jets with Remove the following:

care. They can
O-RING WASHER
– Main jet
easily be scored or
– Needle jet holder
scratched. SPRING
– Needle jet
– Slow jet
Damage to the pilot Turn the pilot screw in and record the number of turns it
screw seat will takes before it seats lightly.
occur if the pilot PILOT
Remove the pilot screw, spring, washer and O-ring. SCREW
screw is tightened NEEDLE JET
against the seat.
MAIN JET
NEEDLE JET
SLOW JET HOLDER
5-12
dummyhead
FUEL SYSTEM
CARBURETOR ASSEMBLY
VACUUM 2.1 N·m (0.2 kgf·m,

CHAMBER 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
1.5 lbf·ft)
COVER WIRE
CLAMP 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
HOSE SE THERMAL
CLAMP VALVE COVER
THROTTLE
CABLE HOLDER SE THERMAL
FLOAT PIN VALVE
FLOAT VALVE
SPRING O-RING
AIR VENT HOSE
FLOAT
VALVE
COVER
NEEDLE HOLDER 2.1 N·m
DIAPHRAGM (0.2 kgf·m,
1.5 lbf·ft)
SPRING
JET NEEDLE
SET PLATE
3.4 N·m
(0.3 kgf·m,
O-RING 2.5 lbf·ft)
SE THERMAL
NEEDLE JET VALVE BODY
PILOT
SCREW O-RING
DIAPHRAGM/ SLOW JET
VACUUM 1.8 N·m (0.2 kgf·m, FLOAT
PISTON 1.3 lbf·ft) WASHER CHAMBER
O-RING
O-RING DRAIN SCREW
NEEDLE JET HOLDER
1.5 N·m (0.2 kgf·m,
2.5 N·m (0.3 kgf·m, MAIN JET 2.1 N·m (0.2 kgf·m, 1.1 lbf·ft)
1.8 lbf·ft) 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
1.5 lbf·ft)
5-13
dummyhead
FUEL SYSTEM
FLOAT CHAMBER
Handle the jets with Install the following:
care. They can WASHER
– Slow jet O-RING
easily be scored or
– Needle jet
scratched.
– Needle jet holder
– Main jet SPRING
Tighten the jets to the specified torque.
TORQUE: PILOT
Slow jet: NEEDLE JET SCREW
1.8 N·m (0.2 kgf·m, 1.3 lbf·ft)
Needle jet holder:
2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) MAIN JET
NEEDLE JET
Main jet: SLOW JET HOLDER
2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Damage to the pilot Install the spring, washer and new O-ring to the pilot
screw seat will screw.
occur if the pilot Return the pilot screw to its original position as noted
screw is tightened during removal.
against the seat. Perform the pilot screw adjustment procedure if a new
pilot screw is installed (page 5-22).
Install the float pin Install the float and float valve in the carburetor body,
with its spline facing then install the float pin through the body and float. FLOAT PIN
the SE thermal
valve side.
FLOAT VALVE SPLINE
Drive in the float pin gently until the height from the float
pin holder (SE thermal valve side) is 0.15–0.55 mm 0.15–0.55 mm
(0.006–0.022 in). (0.006–0.022 in)
Install a new O-ring to the float chamber.

Install the float chamber. O-RING
FLOAT CHAMBER
5-14
dummyhead
FUEL SYSTEM
Install and tighten the float chamber screws to the
specified torque. SCREWS FLOAT
CHAMBER
VACUUM CHAMBER
Install the jet needle, spring and needle holder into the
diaphragm/vacuum piston. JET NEEDLE SPRING
DIAPHRAGM/
VACUUM PISTON NEEDLE HOLDER
Press the needle holder into the vacuum piston and turn
the needle holder clockwise until you feel a click. NEEDLE HOLDER
Be careful not to Install the diaphragm/vacuum piston in the carburetor

damage the jet body, aligning the diaphragm tab with the groove on the Set VACUUM
SPRING
needle. carburetor body. CHAMBER
COVER
Hold the vacuum piston almost full open to prevent the DIAPHRAGM/
diaphragm from being pinched by the vacuum chamber VACUUM
cover. PISTON
Install the compression spring into the diaphragm/
vacuum piston.
Be careful not to Set the boss of the vacuum chamber cover to the
damage the spring. compression spring and install the vacuum chamber
cover.
Align
5-15
dummyhead
FUEL SYSTEM
Install the wire clamp and hose clamp, then tighten the
WIRE CLAMP
screws to the specified torque.
HOSE CLAMP SCREWS
Check that the spring is installed correctly by pushing

the bottom of the piston up with your finger and make SPRING PISTON
sure that the piston returns back in place smoothly.
AIR CUT-OFF VALVE

Install the diaphragm and spring.
DIAPHRAGM SPRING
Install and hold the air cut-off valve cover, being careful
AIR CUT-OFF
not to pinch the diaphragm. VALVE COVER
Install and tighten the screws to the specified torque.
SCREWS
5-16
dummyhead
FUEL SYSTEM
Install the throttle cable holder and tighten the screws to THROTTLE CABLE
the specified torque. HOLDER
SCREWS
STARTING ENRICHMENT (SE)

THERMAL VALVE
Install a new O-ring in the carburetor body groove.
O-RING
Install the SE thermal valve body.

SE THERMAL
Install and tighten the screws to the specified torque. VALVE BODY
SCREWS
Install a new O-ring to the SE thermal valve.

SE THERMAL VALVE
Install the SE thermal valve into the valve body until it is
fully seated.
SE THERMAL
VALVE BODY O-RING
5-17
dummyhead
FUEL SYSTEM
Set the SE thermal valve as shown.
SE THERMAL
VALVE
CARBURETOR
BODY
Install the setting plate onto the SE thermal valve

groove. SCREWS SE THERMAL
Install and tighten the screws to the specified torque. VALVE
SET PLATE
Install the SE thermal valve cover onto the SE thermal

valve. SE THERMAL WIRE CLAMP
VALVE COVER
Secure the SE thermal wire with the wire clamp.
SE THERMAL
VALVE WIRE
HOSES
Connect the drain hose and air cut-off valve vacuum CLAMP VACUUM HOSE
hose to the carburetor.
Secure the vacuum hose with the hose clamp.
DRAIN HOSE
5-18
dummyhead
FUEL SYSTEM
CARBURETOR CLEANING
Remove the following (page 5-8):
– SE thermal valve
– Air cut-off valve
– Diaphragm/vacuum piston
– Float/float valve
– Main jet/needle jet/slow jet
– Pilot screw/spring/washer/O-ring
Cleaning the air and Blow open all air and fuel passages in the carburetor
fuel passages with a body with compressed air.
piece of wire will
damage the
carburetor body.
CARBURETOR INSPECTION
SE THERMAL VALVE
VALVE/NEEDLE INSPECTION
Remove the SE thermal valve (page 5-9).
SE THERMAL
Inspect the valve and needle for stepped wear or VALVE
damage.
NEEDLE VALVE
VALVE THERMOWAX INSPECTION

If the engine has been running, let it cool down (below
35°C (95°F) for 30 minutes or more.
Measure the resistance between the SE thermal valve
connector terminals.
CONNECTION: Yellow – Green/Black
Standard: 4.5 Ω (20°C/68°F)
The SE thermal Replace the SE thermal valve with a new one if

valve might be resistance is out of specification or if there is no
normal if the continuity.
resistance is only
slightly out of
specification.
However, be sure to
check all related
parts for problem.
5-19
dummyhead
FUEL SYSTEM
VALVE OPERATION INSPECTION
If the engine has been running, let it cool down (below
35°C (95°F) for 30 minutes or more.
Insert the vinyl hose into the fuel enrichment circuit and
blow into the hose.
Air should flow into the circuit.
VINYL HOSE
Connect the 12 V battery to the SE thermal valve

connector terminals for 5 minutes. BATTERY
Insert the vinyl hose into the fuel enrichment circuit and
blow into the hose.
Air should not flow into the circuit.
If air flows into the circuit, replace the SE thermal valve.
VINYL HOSE
RESISTOR INSPECTION
Remove the front cover (page 2-9).
Disconnect the SE thermal valve resistor (Green) wire RESISTOR
connector.
Measure the resistance between the Green terminal of
the resistor side and ground.
Standard: 8.6 – 10.5 Ω (20°C/68°F)
If it is out of specification, replace the SE thermal valve
resistor.
WIRE CONNECTOR
AIR CUT-OFF VALVE

Remove the air cut-off valve (page 5-10).
DIAPHRAGM NEEDLE
Check the following:
– diaphragm for pin holes, deterioration or damage
– spring for deterioration
– needle of diaphragm for wear
– air passages for clogging
5-20
dummyhead
FUEL SYSTEM
VACUUM CHAMBER
Remove the vacuum chamber (page 5-11).
JET NEEDLE SPRING
Air can leak out of Check the following:
the vacuum
– Jet needle for stepped wear
chamber if the
– Vacuum piston for wear or damage
diaphragm is
– Diaphragm for pin holes, deterioration or damage
damaged in any
way, even if only a
pin hole.
DIAPHRAGM/
VACUUM PISTON
FLOAT CHAMBER
Remove the float (page 5-11).
FLOAT
Check the float for damage or fuel in the float.
Replace the float if there is fuel in the float.
Inspect the float valve seat for scores, scratches, clogs
and damage.
VALVE SEAT
Check the tip of the float valve where it contacts the

valve seat for stepped wear or contamination. INNER SPRING FLOAT VALVE END
Replace the valve if the tip is worn or contaminated.
Check the float valve inner spring operation by pushing
the float valve end with your finger and make sure that
the float valve end returns back in place smoothly.
Install the float valve and float (page 5-14).
Set the float level With the float valve seated and the float arm just
gauge so that it is touching the valve, measure the float level with the
perpendicular to the special tool.
float chamber face
at the highest point
TOOL:
of the float. Carburetor float level gauge 07401-0010000 TIP
FLOAT LEVEL: 18.5 mm (0.73 in)

The float cannot be adjusted.
Replace the float assembly if the float level is out of
specification.
5-21
dummyhead
FUEL SYSTEM
PILOT SCREW/JETS
Remove the pilot screw and each jet (page 5-11).
– Pilot screw needle for wear or damage
– Pilot screw spring for deterioration
– Each jet for clogging SPRING
– Each passage for clogging
PILOT
NEEDLE JET SCREW
MAIN JET
NEEDLE JET
SLOW JET HOLDER
PILOT SCREW ADJUSTMENT

• The pilot screw is factory pre-set and no adjustment
is necessary unless the pilot screw is replaced.
• The engine must be warm for accurate adjustment.
10 minutes of stop-and-go riding is sufficient.
• Use a tachometer with graduations of 50 min-1 (rpm)
or smaller that will accurately indicate a 50 min-1
(rpm) change.
IDLE DROP PROCEDURE
PILOT SCREW
Damage to the pilot 1. Turn the pilot screw clockwise until it seats lightly,
screw seat will then back it out to the specification given.
occur if the pilot This is an initial setting prior to the final pilot screw
screw is tightened adjustment.
against the seat.
INITIAL OPENING:
Except MX/CO type: 1 5/8 turns out
MX/CO type: 1 3/8 turns out
2. Warm the engine up to operating temperature.
Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect a tachometer
according to the tachometer manufacturer’s
instructions.
4. Start the engine and adjust the idle speed with the
throttle stop screw.
IDLE SPEED: 1,700 ± 100 min-1 (rpm)

5. Turn the pilot screw in or out slowly to obtain the
highest engine speed.
6. Lightly open the throttle 2 or 3 times, then adjust the
idle speed with the throttle stop screw.
7. Turn the pilot screw in gradually until the engine
speed drops by 100 min-1 (rpm)
8. Turn the pilot screw outward to the final opening.
FINAL OPENING:1/8 turns out from the position THROTTLE STOP SCREW
obtained in step 7
9. Readjust the idle speed with the throttle stop screw.
IDLE SPEED: 1,700 ± 100 min-1 (rpm)
5-22
dummyhead
FUEL SYSTEM
INLET PIPE
Remove the carburetor (page 5-6).
NUTS INLET PIPE
Disconnect the vacuum hose from the inlet pipe joint.
– Nuts
– Inlet pipe
– Gasket
Replace the gasket Installation is in the reverse order of removal.
with new one.
VACUUM HOSE GASKET
FUEL TANK
GUIDE FUEL LEVEL SENSOR
Disconnect the fuel level sensor 3P connector. 3P CONNECTOR
Release the fuel level sensor wire from the frame clamp CLAMP
and wire guide.
Release the fuel tray drain hose from the hole of the
rear fender.
DRAIN
HOSE FUEL LEVEL
HOLE SENSOR WIRE
Disconnect the fuel hose and vacuum hose from the
fuel auto valve. FUEL HOSE
FUEL AUTO VALVE

VACUUM HOSE
5-23
dummyhead
FUEL SYSTEM
Remove the fuel tray drain hose, bolts, seat lock
bracket, fuel tank holder and fuel tank.
Route the wire Installation is in the reverse order of removal. FUEL TANK HOLDER
harness and hose
FUEL TRAY
properly (page 1-
13). BOLTS DRAIN HOSE
SEAT LOCK
BRACKET
FUEL TANK
FUEL AUTO VALVE

REMOVAL
Place an approved fuel container and drain the fuel
(page 5-25). FUEL AUTO VALVE
Remove the fuel tank (page 5-23).
Wipe off spilled out Loosen the lock nut and remove the fuel auto valve.
fuel immediately.
LOCK NUT
INSTALLATION
Install the fuel auto valve into the fuel tank.
FUEL AUTO VALVE
Align the joint of fuel auto valve with the punch mark on
the fuel tank.
Tighten the lock nut to the specified torque.
Align LOCK NUT
5-24
dummyhead
FUEL SYSTEM
CLEANING
Remove the fuel strainer screen and O-ring from the
fuel auto valve. FUEL AUTO O-RING
VALVE
FUEL STRAINER
SCREEN
Clean the fuel strainer screen with compressed air.

FUEL STRAINER
SCREEN
Install a new O-ring to the fuel strainer screen.

O-RING FUEL STRAINER
Install the fuel strainer screen onto the fuel auto valve. SCREEN
INSPECTION
Stop the engine.
Wipe the spilled out Disconnect the fuel hose from the carburetor.
fuel.
Check that the fuel does not flow out from the fuel hose.
FUEL HOSE
5-25
dummyhead
FUEL SYSTEM
Disconnect the fuel hose from the fuel auto valve and
connect a suitable fuel drain hose. FUEL AUTO VALVE VACUUM PUMP
Place a suitable container under the fuel drain hose.
Disconnect the vacuum hose from the fuel auto valve
and connect a commercially available vacuum pump to
the diaphragm vacuum outlet.
Fuel should flow out from the fuel hose when vacuum is
applied.
If fuel flow is restricted or does not flow, replace the fuel
auto valve.
5-26
dummytext
6. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION ····························6-2 ENGINE ························································· 6-3
SERVICE INFORMATION ·····························6-2 ENGINE HANGER BRACKET ······················ 6-9
6-1
dummyhead
COMPONENT LOCATION
50 N·m (5.1 kgf·m, 37 lbf·ft)
50 N·m (5.1 kgf·m, 37 lbf·ft)
50 N·m (5.1 kgf·m, 37 lbf·ft)
SERVICE INFORMATION
GENERAL
• Support the engine using a jack or other adjustable support to ease of engine mounting bolt removal.
• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• The following components can be serviced with the engine installed in the frame.
– Cylinder head/valves (page 7-6)
– Cylinder (page 8-3)
– Piston (page 8-4)
– Drive pulley (page 9-7)
– Driven pulley/clutch (page 9-11)
– Kickstarter (page 9-19)
– Final reduction (page 10-3)
– Stator/ignition pulse generator (page 11-3)
– Carburetor (page 5-6)
– Oil pump (page 4-4)
• The following components require engine removal for service.
– Crankcase/crankshaft (page 12-4)
6-2
dummyhead
ENGINE
REMOVAL
– Floor panel (page 2-8) BRAKE CABLE JOINT PIN
– Rear fender (page 2-12)
Remove the rear brake adjusting nut, brake cable, joint
pin and spring.
SPRING ADJUSTING NUT
Remove the air cleaner housing mounting bolts.
BOLTS
Be careful not to Lift up the air cleaner housing and release the rear
damage the brake cable from the cable guide. CABLE GUIDE
connecting hose-to-
housing mating
area.
REAR BRAKE CABLE
Release the rear brake cable and throttle cable from the
cable guides. THROTTLE CABLE
CABLE
GUIDES
REAR BRAKE CABLE
6-3
dummyhead
Loosen the band screw and disconnect the air duct
from the left crankcase cover. CRANKCASE COVER
AIR DUCT BAND SCREW
Wipe off the spilled Disconnect the fuel hose and vacuum hose from the
fuel. fuel auto valve. FUEL HOSE
VACUUM HOSE
Pull the cover off and disconnect the ignition coil wire
COVER
connectors.
WIRE
CONNECTORS
6-4
dummyhead
Disconnect the SE thermal valve 2P (Red) and
alternator/ignition pulse generator 3P connectors. BOLT/ CONNECTORS
Release the following from the wire guide: GROUND CLAMPS
CABLES
– Battery negative (–) cable
– Starter motor cable
– Alternator wire
– Ground cable
– Ignition coil primary wire
Release the alternator wire band and SE thermal valve
wire band.
Release the following from the clamps:
– Ground cable
– Alternator wire
WIRE BANDS WIRE GUIDE
Loosen the lock nut and release the throttle cable from
the cable holder. HOLDER
Disconnect the throttle cable end from the throttle drum.
LOCK NUT CABLE END
Support the engine with jack.

To avoid damage to Remove the rear shock absorber upper bolt.
the rear shock
absorber bolt
threads, sightly lift
the rear wheel.
UPPER BOLT
6-5
dummyhead
Remove the left engine hanger bolt.
Remove the right engine hanger bolt/collar. RIGHT ENGINE
Remove the engine by releasing the engine hanger HANGER BOLT/
bracket from the frame and slightly pulling the engine COLLAR
straight back.
INSTALLATION
Set the engine straight with the frame and insert the
engine hanger bracket bushings to the grooves of the
frame while adjusting the engine height by jack.
Install the right engine hanger bolt and collar.
Install the left engine hanger bolt.
LEFT ENGINE
HANGER BOLT
To avoid damage to Install the rear shock absorber upper bolt.

the rear shock
Tighten the right and left engine hanger bolts to the
absorber bolt
specified torque.
threads, sightly lift
the rear wheel. TORQUE: 50 N·m (5.1 kgf·m, 37 lbf·ft)
Tighten the rear shock absorber upper mounting bolt.
UPPER BOLT
6-6
dummyhead
Route the wire Route the following through the wire guide:
harness properly
– Battery negative (–) cable BOLT/ CONNECTORS
(page 1-13).
– Starter motor cable GROUND CLAMPS
– Alternator wire CABLES
– Ground cable
– Ignition coil primary wire
Secure the alternator wire band and SE thermal valve
wire band into the frame hole.
Route the following through the clamps:
– Ground cable
– Alternator wire
Install the ground cables and tighten the bolt.
Connect the SE thermal valve 2P (Red) connector and
alternator/ignition pulse generator 3P connector.
WIRE BANDS WIRE GUIDE
Connect the throttle cable end to the throttle drum and

install the throttle cable to the cable holder. THROTTLE
DRUM
Tighten the lock nut.
CABLE HOLDER LOCK NUT CABLE END
Connect the ignition coil wire connectors and pull the

COVER
cover back.
WIRE
CONNECTORS
6-7
dummyhead
Connect the fuel hose and vacuum hose to the fuel auto
valve. FUEL HOSE
VACUUM HOSE
Connect the air duct to the left crankcase cover by

aligning the air duct cut-off with the left crankcase cover CRANKCASE COVER
tab. Align
Tighten the band screw until the band ends clearance is AIR DUCT
6.0 – 8.0 mm (0.24 – 0.31 in).
BAND SCREW
6.0 – 8.0 mm (0.24 – 0.31 in)
Set the rear brake cable and throttle cable to the cable
guides. THROTTLE CABLE
CABLE
GUIDES
REAR BRAKE CABLE
Lift up the air cleaner housing and secure the rear

brake cable with the cable guide. CABLE GUIDE
REAR BRAKE CABLE
6-8
dummyhead
Install and tighten the air cleaner housing mounting
bolts.
BOLTS
Install the spring, joint pin, brake cable and adjusting

nut. BRAKE CABLE JOINT PIN
Adjust the following:
– Rear brake (page 3-12)
– Throttle grip freeplay (page 3-3)
– Rear fender (page 2-12)
– Floor panel (page 2-8)
SPRING ADJUSTING NUT
ENGINE HANGER BRACKET

REMOVAL
Remove the engine (page 6-3).
Disconnect the crankcase breather hose from the air CRANKCASE
cleaner housing. BREATHER HOSE
Remove the following from the right side engine hanger

bracket guide: RIGHT SIDE ENGINE
– Battery negative (–) cable HANGER BRACKET GUIDE
– Main wire harness
– Ground cable
Remove the following from the left side engine hanger
bracket guide:
– Fuel hose
– Vacuum hoses
– Crankcase breather hose
LEFT SIDE ENGINE HANGER
BRACKET GUIDE
6-9
dummyhead
Remove the bolt and ignition coil from the engine
hanger bracket. IGNITION COIL
BOLT
Remove the hole cap from the cooling fan cover.

Remove the engine hanger bracket nut from the left
side of engine while holding the bolt from the right side
of the engine.
Pull out the engine hanger bracket bolt.
Remove the engine hanger bracket from the engine.
INSTALLATION
Set the engine hanger bracket onto the engine.
Install the engine hanger bracket bolt from the right side ENGINE HANGER BRACKET NUT
of the engine.
Install the engine hanger bracket nut, but do not tighten
yet.
ENGINE HANGER BRACKET BOLT
HOLE CAP
Install the ignition coil to the engine hanger bracket by

IGNITION COIL
aligning the boss on the ignition coil and cut-out of the
engine hanger bracket.
Align
6-10
dummyhead
Install and tighten the bolt.
IGNITION COIL
BOLT
Route the wire Route the following through the left side engine hanger
harness properly bracket guide: RIGHT SIDE ENGINE
(page 1-13). HANGER BRACKET GUIDE
– Crankcase breather hose
– Vacuum hoses
– Fuel hose
Route the wire Route the following through the right side engine
harness properly hanger bracket guide:
(page 1-13).
– Harness wire
– Ground cable
LEFT SIDE ENGINE HANGER
Connect the crankcase breather hose to the air cleaner BRACKET GUIDE
housing.
Install the engine (page 6-6).
Tighten the engine hanger bracket nut to the specified
torque while holding the bolt from the right side of the
engine.
Install the hole cap to the cooling fan cover.
ENGINE HANGER BRACKET NUT
ENGINE HANGER BRACKET BOLT
HOLE CAP
6-11
dummyhead
INSPECTION
CUSHION RUBBERS
– Bushing collars for wear or damage
– Damper rubbers for deterioration, crack or damage
– Cushion rubbers for wear or damage
BUSHING COLLARS/
DAMPER RUBBERS

– Bushing collars for wear or damage
– Damper rubbers for deterioration, crack or damage
BUSHING
COLLARS/
DAMPER
RUBBERS
6-12
dummytext
7. CYLINDER HEAD/VALVES
COMPONENT LOCATION ····························7-2 CYLINDER HEAD COVER ··························· 7-4 7
SERVICE INFORMATION ·····························7-3 INTAKE/EXHAUST SHROUDS ···················· 7-5
TROUBLESHOOTING···································7-3 CAMSHAFT/CYLINDER HEAD ···················· 7-6
CYLINDER COMPRESSION TEST···············7-4 CAM CHAIN TENSIONER LIFTER············· 7-20
7-1
dummyhead
COMPONENT LOCATION
13 N·m (1.3 kgf·m, 10 lbf·ft)
8 N·m (0.8 kgf·m, 5.9 lbf·ft)
24 N·m (2.4 kgf·m, 18 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
7-2
dummyhead
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves, rocker arms and camshaft.
• This services can be done with the engine installed in the frame. Remove the shock absorber lower mounting bolt (page 14-5)
and slightly lift up the rear side of the engine to prevent the intake manifold stud bolts from interfering with frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before
assembling cylinder head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not tap the cylinder
head cover and cylinder head too hard during removal.
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by
tracing engine noises to the top-end with a sounding rod or stethoscope.
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for
a seized piston ring (page 8-8).
Compression too low, hard starting or poor performance at low speed
• Valves:
– Incorrect valve adjustment
– Burned or bent valve
– Incorrect valve timing
– Broken valve spring
– Uneven valve seating
– Valve stuck open
• Cylinder head:
– Leaking or damaged cylinder head gasket
– Warped or cracked cylinder head
– Loose spark plug
• Worn piston or piston rings (page 8-8)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Worn piston or piston rings (page 8-8)
Excessive noise
• Incorrect valve adjustment
• Sticking valve or broken valve spring
• Excessively worn valve seat
• Worn or damaged camshaft
• Worn or damaged cam chain
• Worn cam sprocket teeth
• Worn rocker arm and/or shaft
• Worn or damaged cam chain tensioner
Rough idle
• Low cylinder compression
7-3
dummyhead
CYLINDER COMPRESSION TEST
Warm up the engine to normal operating temperature.
Stop the engine and remove the spark plug cap and
spark plug (page 3-5).
Install a compression gauge into the spark plug hole.
To avoid Open the throttle all the way and crank the engine with
discharging the the starter until the gauge reading stops rising.
battery, do not The maximum reading is usually reached within 4 – 7
operate the starter seconds.
motor for more than
7 seconds.
COMPRESSION PRESSURE:
1,275 kPa (13.0 kg/cm2, 185 psi) at 570 min-1 (rpm)
COMPRESSION
If compression is high, it indicates that carbon deposits GAUGE
have accumulated on the combustion chamber and/or
the piston crown.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of
clean engine oil into the cylinder through the spark plug
hole and recheck the compression.
If the compression increases from the previous value,
check the cylinder, piston and piston rings.
• Leaking cylinder head gasket
• Worn piston ring
• Worn cylinder and piston
If compression is the same as the previous value, check
the valves for leakage.
CYLINDER HEAD COVER

REMOVAL
Remove the center cover (page 2-5).
CRANKCASE CYLINDER
Disconnect the crankcase breather hose. BREATHER HOSE HEAD COVER
Remove the special bolts/mounting rubbers and
cylinder head cover.
Remove the rubber seal from the cylinder head cover.
RUBBER SPECIAL BOLTS/

SEAL MOUNTING RUBBERS
INSTALLATION
Make sure the rubber seal is in good condition and
replace it if necessary.
Install the rubber seal into the grooves on the cylinder
head cover.
RUBBER SEAL
7-4
dummyhead
Make sure the mounting rubbers are in good condition
and replace them if necessary. "UP" MARK
Install the mounting rubbers with their "UP" mark facing

up.
MOUNTING RUBBER
Install the cylinder head cover onto the cylinder head.

CRANKCASE CYLINDER
Install the special bolts and tighten them to the specified BREATHER HOSE
torque. HEAD COVER

Connect the crankcase breather hose to the cylinder
head cover.
Install the center cover (page 2-5).
SPECIAL BOLTS
INTAKE/EXHAUST SHROUDS
REMOVAL
WIRE GUIDES
– Under cover (page 2-7)
– Muffler (page 2-13)
– Inlet pipe (page 5-23)
– Cooling fan cover (page 11-3)
Release the following from the wire guides:
– Alternator wire
– Ground cable
– Spark plug wire
Release the wire bands from the stays.
Release the rear brake cable, throttle cable and WIRE BANDS
breather hose from the clamps.
Remove the two mounting bolts and special bolt from
the shroud. CLAMPS
Remove the intake/exhaust shrouds.
7-5
dummyhead
INSTALLATION
Set the intake/exhaust shrouds in position by inserting
the right side of exhaust shroud to the groove of the
intake shroud and aligning the tab of the left side of
exhaust shroud with the slot of the intake shroud.
Install the mounting bolts and special bolt to the shroud,
then tighten them to the specified torque.
TORQUE:
MOUNTING BOLT
8 N·m (0.8 kgf·m, 5.9 lbf·ft)
SPECIAL BOLT
13 N·m (1.3 kgf·m, 10 lbf·ft)
Route the cable and wire properly (page 1-13).
INTAKE SHROUD
MOUNTING BOLTS
Right side: Left side:
SPECIAL BOLT
Insert EXHAUST SHROUD Align
CAMSHAFT/CYLINDER HEAD
CAMSHAFT/CYLINDER HEAD
REMOVAL
• When removing the camshaft holder nuts, always
replace the cylinder head and cylinder gasket with
new ones.
• This services can be done with the engine installed
in the frame. Remove the shock absorber lower
mounting bolt (page 14-5) and slightly lift up the rear
side of the engine to prevent the intake manifold
stud bolts from interfering with frame.
– Cylinder head cover (page 7-4) "T" MARK
– Intake/exhaust shrouds (page 7-5)
Turn the crankshaft Rotate the crankshaft clockwise and align the "T" mark
clockwise only. on the flywheel with the index notch of the right
crankcase.
Make sure that the piston is at TDC (Top Dead Center)
on the compression stroke.
The rocker arms should be loose.
If the rocker arms are tight, rotate the crankshaft one
full turn and realign the "T" mark with the index notch.
INDEX NOTCH
7-6
dummyhead
Make sure that the timing mark (index line) aligns with
the top surface of the cylinder head. TIMING MARK
Remove the cam chain tensioner lifter screw and

sealing washer from the tensioner lifter. SCREW
SEALING
WASHER
Install the special tool into the tensioner lifter body and
turn the tool clockwise until it stops turning. TENSIONER LIFTER STOPPER
Hold the tensioner lifter by pushing the tool while
aligning the tabs of the tool with the grooves of the
tensioner lifter.
TOOL:
Tensioner lifter stopper 070MG-0010100
Remove the bolts from the cylinder head.

Loosen the camshaft holder nuts in a crisscross pattern HOLDER
in two or three steps.
Remove the nuts and the plates.
Remove the camshaft holder.
NUTS PLATE BOLTS
7-7
dummyhead
Remove the cam chain from the cam sprocket.
Attach a piece of wire to the cam chain to prevent it CAM CHAIN
from falling into the crankcase.
Remove the camshaft.
Remove the dowel pins from the cylinder head.
DOWEL PINS CAM SPROCKET/SHAFT
Remove the cylinder head.
CYLINDER HEAD
Remove the cylinder head gasket and dowel pins.

GASKET
Remove the cam chain guide from the cylinder.
Check the cam chain guide for excessive wear or
damage.
DOWEL PINS CAM CHAIN GUIDE
CYLINDER HEAD/CAMSHAFT
INSTALLATION
Clean the mating surface of the cylinder and cylinder
head. GROOVES
Install the cam chain guide by aligning the bosses of the
cam chain guide with the grooves of the cylinder.
BOSSES
7-8
dummyhead
Install the dowel pins and a new gasket onto the
cylinder. GASKET
DOWEL PINS
Route the cam chain through the cylinder head and

install the cylinder head onto the cylinder. CAM CHAIN
CYLINDER HEAD
Turn the crankshaft Make sure that the "T" mark of the flywheel aligns with
clockwise only. the index notch. "T" MARK
INDEX NOTCH
Apply engine oil to the cam chain and cam sprocket

CAM SPROCKET TIMING MARK
teeth.
Install the cam chain onto the cam sprocket/shaft with
its hole facing up while aligning the timing mark (index
line) on the cam sprocket with the top surface of the
cylinder head.
CAM CHAIN HOLE
7-9
dummyhead
Install the dowel pins.
Lubricate the cam lobes with molybdenum oil solution. CAM LOBES
Apply clean engine oil to the camshaft bearings.
DOWEL PINS
Apply clean engine oil to the camshaft holder nut

threads and seating surface. HOLDER MOUNTING
BOLTS
Be sure that the Install the camshaft holder with "EX" mark facing the
exhaust rocker arm exhaust side.
does not contact the
Install the plates and camshaft holder nuts, then tighten
decompressor cam
the nuts in crisscross pattern in 2 or 3 steps.
lobe.
Tighten the cylinder head mounting bolts.
"EX" MARK NUTS PLATE
Remove the tensioner lifter stopper from the cam chain

tensioner lifter. TENSIONER SCREW
Install a new sealing washer/screw to the cam chain LIFTER STOPPER
tensioner lifter and tighten the bolt.
– Intake/exhaust shrouds (page 7-6)
– Cylinder head cover (page 7-4)
SEALING
WASHER
CAMSHAFT HOLDER DISASSEMBLY

Screw a 5 mm screw into the threaded hole in the
rocker arm shaft and pull it out of the camshaft holder. STOPPER PLATE SCREW
Remove the rocker arm stopper plate from the
camshaft holder.
Remove the rocker arms from the camshaft holder.
ROCKER ARMS SHAFTS
7-10
dummyhead
CAMSHAFT HOLDER ASSEMBLY
STOPPER PLATE
VALVE ADJUSTING SCREW
LOCK NUT
EXHAUST
ROCKER ARM
ROCKER ARM SHAFT
CAMSHAFT HOLDER
INTAKE
ROCKER ARM SHAFT
Apply engine oil to the rocker arms and shafts sliding

surfaces. STOPPER PLATE
Apply engine oil to the rocker arm slipper areas.
Set the rocker arms stopper plate and rocker arm onto
the holder as shown.
Install the rocker arm shafts through the holes of the
rocker arm and stopper.
ROCKER ARMS SHAFTS
Turn the intake rocker arm shaft using the screw driver
to align the cut-out of the intake rocker arm shaft and Align INTAKE ROCKER
the hole of the cam shaft holder. ARM SHAFT
SCREW DRIVER
7-11
dummyhead
CYLINDER HEAD DISASSEMBLY
Remove the spark plug (page 3-5).
VALVE SPRING COMPRESSOR
To prevent loss of Remove the valve cotters using the valve spring
tension, do not compressor.
compress the valve
springs more than
TOOL:
necessary to Valve spring compressor 07757-0010000
remove the cotters.
COTTERS
RETAINER
Mark all parts Remove the valve spring compressor, then remove the
during disassembly following: VALVE
so they can be
– Cotters
placed back in their
– Valve spring retainers
original locations.
– Valve springs (Outer) STEM SEAL
– Valve springs (Inner)
– Valve spring seats OUTER SPRING
– Valves
– Valve stem seals SPRING SEAT
INNER SPRING
RETAINER
Avoid damaging the Remove the carbon deposits from the combustion
mating and valve chamber and clean off the gasket material from the COMBUSTION CHAMBER
seat surfaces. mating surface.
7-12
dummyhead
CYLINDER HEAD ASSEMBLY
COTTERS
RETAINER
INNER SPRING
OUTER SPRING
STEM SEAL
SPRING SEAT
INTAKE VALVE
EXHAUST VALVE
Blow through the oil passage in the cylinder head with

compressed air. VALVE
Apply clean engine oil to the inner surface of new valve
stem seals.
Install the valve spring seats and new valve stem seals.
STEM SEAL
Coat the valve stem sliding surface with clean engine
oil. OUTER SPRING
Insert the valves into the valve guide while turning it
slowly to avoid damage to the valve stem seal. SPRING SEAT
INNER SPRING
RETAINER
Install the valve springs with the tightly wound coils

facing the combustion chamber. OUTER SPRING INNER SPRING
Tightly wound coils facing the

combustion chamber side
7-13
dummyhead
Install the valve spring retainer.
VALVE SPRING COMPRESSOR
Grease the cotters Install the valve cotters using the valve spring
to ease installation. compressor.
To prevent loss of
tension, do not
TOOL:
compress the valve Valve spring compressor 07757-0010000
spring more than
necessary to install
the cotters.
COTTERS
RETAINER
Support the cylinder Place a suitable tool onto the valve stem.
head above the VALVE STEM
Tap the tool gently to seat the cotters firmly using a
work bench surface
hammer.
to prevent valve
damage. Install the spark plug (page 3-5).
COTTERS
INSPECTION
CAMSHAFT
Turn the outer race of each camshaft bearing with your
finger. The bearing should turn smoothly and quietly. BEARINGS
Also check that the bearing inner race fits tightly on the
camshaft.
Replace the camshaft assembly if the bearing does not
turn smoothly, quietly, or if they fit loosely on the
camshaft.
7-14
dummyhead
Check the cam lobe for excessive wear and damage.
Measure the height of each cam lobe.
SERVICE LIMIT:
IN: 29.30 mm (1.154 in)
EX: 29.00 mm (1.142 in)
CAM LOBE
DECOMPRESSOR CAM
Turn the decompressor cam with your finger.
Make sure the decompressor cam only turn clockwise DECOMPRESSOR CAM
as shown and does not turn counterclockwise.
If the decompressor cam is faulty, replace the camshaft
as an assembly.
ROCKER ARM/SHAFT
Check the rocker arm shafts and rocker arms for wear,
damage or clogged oil hole.
Measure the I.D. of each rocker arm.
SERVICE LIMIT: IN/EX: 10.10 mm (0.398 in)
Measure the O.D. of each rocker arm shaft.
Calculate the rocker arm-to-shaft clearance.
Check the stopper plate and spring for wear or damage.

Check that the stopper operates smoothly as shown.
STOPPER
7-15
dummyhead
CYLINDER HEAD
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight
edge and feeler gauge.
VALVE SPRING
Measure the free length of the valve springs.
SERVICE LIMIT:
Inner: 29.1 mm (1.15 in)
Outer: 31.5 mm (1.24 in)
Replace the spring if they are shorter than the service
limit.
VALVE/VALVE GUIDE
Check that the valve moves smoothly in the guide.
Check each valve for bends, burns, scratches or
abnormal wear.
Measure each valve stem O.D. and record it.
SERVICE LIMIT:
IN/EX: 4.90 mm (0.193 in)
Always rotate the Ream the valve guide to remove any carbon build up
reamer clockwise, before measuring the guide. VALVE GUIDE REAMER
never Insert the reamer from the combustion chamber side of
counterclockwise the head and always rotate the reamer clockwise.
when installing,
removing and
TOOL:
reaming. Valve guide reamer 07984-MA60001
7-16
dummyhead
Measure each valve guide I.D. and record it.
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the stem-to-guide clearance.
SERVICE LIMIT:
IN: 0.08 mm (0.003 in)
EX: 0.10 mm (0.004 in)
Inspect and reface If the stem-to-guide clearance exceeds the service limit,
the valve seats determine if a new guide with standard dimensions
whenever the valve would bring the clearance within tolerance.
guides are replaced If so, replace any guides as necessary and ream to fit. VALVE GUIDE
(page 7-18). If the stem-to-guide clearance exceeds the service limit
with new guide, also replace the valve.
VALVE GUIDE REPLACEMENT
Chill the new valve guides in a freezer for about 1 hour.
Heat the cylinder head to 130 – 140 °C (275 – 290 °F) VALVE GUIDE DRIVER
Be sure to wear
heavy gloves to with a hot plate or oven. Do not heat the cylinder head
avoid burns when beyond 150 °C (300 °F). Use temperature indicator
handling the heated sticks, available from welding supply stores, to be sure
cylinder head. the cylinder head is heated to the proper temperature.
Using a torch to Support the cylinder head and drive the valve guides
heat the cylinder out of the cylinder head from the combustion chamber
head may cause side.
warpage.
TOOL:
Valve guide driver 07942-MA60000
Remove the O-ring from the valve guide.
VALVE GUIDE
O-RING
7-17
dummyhead
Take out the new valve guides from the freezer.
Install a new O-ring to the new valve guide.
Drive the new guides from the camshaft side while the VALVE GUIDE DRIVER
cylinder head is still heated.
TOOL:
Valve guide driver 07942-MA60000
Let the cylinder head cool to room temperature.
VALVE GUIDE
O-RING
Ream the new valve guides after installation.

VALVE GUIDE REAMER
Take care not to tilt Insert the reamer from the combustion chamber side of
or lean the reamer the head and also always rotate the reamer clockwise.
in the guide while
reaming.
TOOL:
Use cutting oil on Valve guide reamer 07984-MA60001
the reamer during Clean the cylinder head thoroughly to remove any
this operation. metal particles after reaming and reface the valve seat
(page 7-19).
VALVE SEAT INSPECTION

Clean the intake and exhaust valves thoroughly to
remove carbon deposits. HAND-LAPPING TOOL
Apply a light coat of Prussian Blue to the valve seats.

Tap the valve against the valve seat several times using
a hand-lapping tool, without rotating the valve, to make
a clear pattern.
7-18
dummyhead
The valves cannot Remove the valve and inspect the valve seat face.
be ground. If the The valve seat contact should be within the specified
valve face is burned width and even all around the circumference.
or badly worn or if it
contacts the seat STANDARD: 1.0 mm (0.04 in)
unevenly, replace SERVICE LIMIT: 1.6 mm (0.06 in)
the valve. If the valve seat width is not within specification, reface
the valve seat (page 7-19).
Inspect the valve seat face for:
• Damaged face:
– Replace the valve and reface the valve seat SEAT WIDTH
• Uneven seat width:
– Bent or collapsed valve stem; Replace the valve
and reface the valve seat
• Contact area (too low or too high area):
– Reface the valve seat
VALVE SEAT REFACING
Reface the valve seat using the following tools.
TOOLS:
Cutter holder, 5.0 mm 07781-0010400
Seat cutter, 27.5 mm (45° IN) 07780-0010200
Seat cutter, 24 mm (45° EX) 07780-0010600
Flat cutter, 28 mm (32° IN) 07780-0012100
Flat cutter, 25 mm (32° EX) 07780-0012000
Interior cutter, 26 mm (60° IN/EX) 07780-0014500
VALVE SEAT WIDTH: 1.0 mm (0.04 in)
• Follow the refacer manufacturer’s operating

instructions.
• Be careful not to grind the seat more than
necessary. Old seat width
1. Use a 45° seat cutter, remove any roughness or
irregularities from the seat.
2. Use a 32° flat cutter, remove the top 1/4 of the 32°
existing valve seat material.
3. Use a 60° interior cutter, remove the bottom 1/4 of
the existing valve seat material. Old seat width
4. Using a 45° seat cutter, cut the seat to the proper
width.
5. After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.
• Excessive lapping pressure may deform or damage HAND-LAPPING 60°

the seat. TOOL
• Change the angle of lapping tool [1] frequently to
prevent uneven seat wear.
• Do not allow lapping compound to enter the guides.
After lapping, wash any residual compound off the
cylinder head and valve and recheck the seat contact.
7-19
dummyhead
CAM CHAIN TENSIONER LIFTER
REMOVAL
Remove the intake shroud (page 7-5).
Remove the tensioner lifter bolt and the sealing washer. BOLT
SEALING
WASHER
Install the special tool into the tensioner lifter body and
turn the tool clockwise until it stops turning. TENSIONER LIFTER STOPPER
Hold the tensioner lifter by pushing the tool while
aligning the tabs of the tool with the grooves of the
tensioner lifter.
TOOL:
Tensioner lifter stopper 070MG-0010100
Remove the two bolts, cam chain tensioner lifter and

the gasket. BOLTS
TENSIONER
INSTALLATION LIFTER
Install the tensioner lifter stopper and turn the tensioner
shaft clockwise with it to retract the tensioner fully.
Install a new gasket and cam chain tensioner lifter.
GASKET
Install and tighten the bolts.

Remove the tensioner lifter stopper. TENSIONER SCREW
Install a new sealing washer/screw to the cam chain LIFTER STOPPER
tensioner lifter and tighten the screw.
Install the intake shroud (page 7-6).
SEALING
BOLTS WASHER
7-20
dummyhead
INSPECTION
Check the cam chain tensioner lifter operation:
TENSIONER SHAFT TENSIONER
– The tensioner shaft should not go into the body LIFTER STOPPER
when it is pushed.
– When it is turned clockwise with the tensioner lifter
stopper, the tensioner shaft should be pulled into the
body. The shaft should protrude from the body as
soon as the tensioner lifter stopper is released.
TENSIONER LIFTER
7-21
dummyhead
MEMO
dummytext
8. CYLINDER/PISTON
COMPONENT LOCATION ····························8-2 CYLINDER ···················································· 8-3

8
SERVICE INFORMATION ·····························8-2 PISTON ························································· 8-4
TROUBLESHOOTING···································8-2
8-1
dummyhead
CYLINDER/PISTON
COMPONENT LOCATION
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
• This section covers maintenance of the cylinder and piston.
• Be careful not to damage mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal.
• Take care not to damage the cylinder wall and piston.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
• When removing the piston, clean carbon and sludge from the top of the cylinder.
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
• Worn, stuck or broken piston ring
• Worn or damaged cylinder and piston
• Bent connecting rod
Compression too high, overheating or knocking
• Excessive carbon build-up on piston head or on combustion chamber
Excessive smoke
• Worn cylinder, piston or piston ring
• Improper installation of piston rings
• Scored or scratched piston or cylinder wall
Abnormal noise
• Worn piston pin or piston pin hole
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
Piston ring sticking/scuffing, bearing damage
• Clogged oil gallery or oil strainer screen
• Internal oil leak
• Not using recommended engine oil
8-2
dummyhead
CYLINDER/PISTON
CYLINDER
REMOVAL
Attach a piece of Remove the cylinder head (page 7-6).
wire to the cam
Remove the cylinder. CYLINDER
chain to prevent it
from falling into the
crankcase. Be
careful not to
damage the mating
surfaces by using a
screwdriver when
disassembling the
cylinder.
Remove the gasket and dowel pins.

GASKET
When cleaning the Clean any gasket material from the cylinder mating
cylinder mating surface of the crankcase.
surface, place a
shop towel over the
cylinder opening to INSTALLATION
prevent dust or dirt
from entering the Install dowel pins and a new gasket.
engine.
DOWEL PINS
Apply clean engine oil to the cylinder inner surface,

piston and piston rings.
CYLINDER
Attach a piece of Install the cylinder over the piston while compressing
wire to the cam the piston rings with your finger.
chain to prevent it
Install the cylinder head (page 7-8).
from falling into the
crankcase.
PISTON/PISTON RING
8-3
dummyhead
CYLINDER/PISTON
INSPECTION
Remove the cylinder (page 8-3).
Inspect the cylinder bore for wear or damage. Y
Measure the cylinder I.D. in the X and Y axis at three
levels.
Take the maximum reading to determine the cylinder X
wear. TOP

Calculate the taper and out-of-round at three levels in MIDDLE
the X and Y axis. Take the maximum reading to
determine both measurements.
SERVICE LIMIT: BOTTOM
Taper: 0.05 mm (0.002 in)
Out of round: 0.05 mm (0.002 in)
The cylinder must be rebored and an oversize piston/
piston rings fitted if the service limits are exceeded.
The following oversize pistons/piston rings are
available:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
0.75 mm (0.030 in)
1.00 mm (0.039 in)
The piston to cylinder clearance for the oversize piston
must be: 0.010 – 0.040 mm (0.0004 – 0.0016 in).
Check the cylinder for warpage with a straight edge and
feeler gauge in the directions as shown.
PISTON
REMOVAL
Remove the cylinder (page 8-3).
PISTON PIN CLIP
Place a shop towel Remove the piston pin clips with the pliers.
over the opening of
the crankcase to
prevent the piston
pin clips from falling
into the crankcase.
8-4
dummyhead
CYLINDER/PISTON
Push the piston pin out of the piston and connecting
rod, then remove the piston. PISTON PIN
Do not damage the Spread each piston ring and remove it by lifting up at a
piston ring by point opposite the gap.
spreading the ends
too far.
PISTON RING
Never use a wire Clean carbon deposits from the ring grooves with a ring
brush, it will scratch that will be discarded.
the groove.
8-5
dummyhead
CYLINDER/PISTON
INSTALLATION
Apply clean engine oil to each ring and ring groove.
Be careful not to Carefully install the piston rings into the piston ring
damage the piston grooves with the markings facing up.
and rings.
• Do not confuse the top and second rings.
• To install the oil ring, install the spacer first, then
install the side rails.
Stagger the piston ring end gaps 120 degrees apart
from each other.
Stagger the side rail end gaps as shown.
MARK
TOP RING
SECOND RING
120°
MARK 120° TOP RING
120°
SECOND RING
OIL RING
SPACER
SIDE RAILS
20 mm or
more
20 mm or
more
Apply clean engine oil to the connecting rod small end

hole.
CONNECTING ROD
8-6
dummyhead
CYLINDER/PISTON
Install the piston with the "IN" mark facing the intake
side. PISTON PIN "IN" MARK
Apply clean engine oil to the piston pin and install it.
Place a shop towel Install the new piston pin clips.

over the opening of
• Make sure the piston pin clips are seated securely.
the crankcase to PISTON CUT-OUT
• Do not align the piston pin clip end gap with the
prevent the piston
piston cut-out. CLIP
pin clips from falling
into the crankcase.
CUT OUT
PISTON PIN CLIP
8-7
dummyhead
CYLINDER/PISTON
INSPECTION
Inspect the piston rings for movement by rotating the
rings. The rings should be able to move in their grooves
without catching.
Push the ring until the outer surface of the piston ring is
nearly flush with the piston and measure the ring-to-
groove clearance.
SERVICE LIMIT:
Top/Second: 0.09 mm (0.004 in)
FEELER GAUGE
Insert each piston ring into the bottom of the cylinder

squarely using the piston. PISTON RING FEELER GAUGE
Measure the ring end gap.
SERVICE LIMIT:
Top: 0.50 mm (0.020 in)
Second: 0.60 mm (0.024 in)
Measure the piston O.D. at the point 10 mm (0.39 in)

from the bottom and 90° to the piston pin hole.
10 mm (0.39 in)
Calculate the cylinder-to-piston clearance (cylinder I.D.:
See page 8-4).
Measure the piston pin bore.

Take the maximum reading to determine I.D.
Measure the piston pin O.D. at piston and connecting
rod sliding areas.
Calculate the piston-to-piston pin clearance.
8-8
dummyhead
CYLINDER/PISTON
Measure the connecting rod small end I.D.

Calculate the connecting rod-to-piston pin clearance.
8-9
dummyhead
MEMO
dummytext
9. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
COMPONENT LOCATION ····························9-2 DRIVE BELT ················································· 9-7
SERVICE INFORMATION ·····························9-3 DRIVE PULLEY············································· 9-7

9
TROUBLESHOOTING···································9-3 CLUTCH/DRIVEN PULLEY ························ 9-11
LEFT CRANKCASE COVER ························9-4 KICKSTARTER ··········································· 9-19
9-1
dummyhead

COMPONENT LOCATION
59 N·m (6.0 kgf·m, 44 lbf·ft)
49 N·m (5.0 kgf·m,

36 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
14 N·m (1.4 kgf·m, 10 lbf·ft)
9-2
dummyhead

SERVICE INFORMATION
GENERAL
• This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch.
• These services can be done with the engine installed in the frame.
• Avoid getting grease and oil on the drive belt and drive/driven pulley faces in order to prevent belt slippage.
• Do not apply grease to the weight rollers.
TROUBLESHOOTING
Engine starts but scooter won’t move
• Worn drive belt
• Damaged ramp plate
• Worn or damaged clutch shoes
• Broken driven face spring
Engine stalls or scooter creeps
• Broken clutch shoe spring
Poor performance at high speed or lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight rollers
• Contaminated pulley faces
9-3
dummyhead

LEFT CRANKCASE COVER
REMOVAL
Remove the air cleaner (page 5-4).
Loosen the band screw and disconnect the air duct LEFT CRANKCASE
from the left crankcase cover. COVER
AIR DUCT BAND SCREW
Before removing the kickstarter pedal, mark the pedal

and spindle for proper installation position. PINCH BOLT
Remove the kickstarter pinch bolt and kickstarter pedal.
KICKSTARTER PEDAL MARK
Remove the bolts and left side outer cover.

LEFT SIDE OUTER COVER
BOLTS
Remove the bolts and left crankcase cover.

BOLTS
9-4
dummyhead

Remove the two dowel pins and gasket.
Clean the gasket mating surface.
GASKET DOWEL PINS
Remove the collar and washer.
INSTALLATION
Install the collar and washer.
WASHER COLLAR
Install two dowel pins and a new gasket.
GASKET DOWEL PINS
Install the left crankcase cover onto the left crankcase

by aligning the dowel pins with the holes.
Install the bolts and tighten the bolts to the specified
torque in a crisscross pattern in 2 or 3 steps.
BOLTS
9-5
dummyhead

Install the left side outer cover and tighten the bolts.
LEFT SIDE OUTER COVER
BOLTS
Install the kickstarter pedal in its original position as

marked during removal and align the bolt hole on the
kickstarter pedal with the groove on the kickstarter KICKSTARTER SPINDLE Align
spindle.
Install and tighten the kickstarter pinch bolt to the
specified torque:
KICKSTARTER PEDAL BOLT
KICKSTARTER PEDAL MARK
Connect the air duct to the left crankcase cover by

aligning the air duct cut-off with the left crankcase cover LEFT CRANKCASE COVER Align
tab.
AIR DUCT
Tighten the band screw until the band ends clearance is
6.0 – 8.0 mm (0.24 – 0.31 in).
BAND SCREW
6.0 – 8.0 mm (0.24 – 0.31 in)
9-6
dummyhead

DRIVE BELT
REPLACEMENT
• The drive belt can be serviced with the engine
installed in the frame.
Remove the clutch/driven pulley (page 9-11).
Remove the drive belt and replace it with a new one. DRIVE BELT
Install the clutch/driven pulley (page 9-11).
DRIVE PULLEY
REMOVAL
Remove the left crankcase cover (page 9-4).
DRIVE PULLEY FACE NUT/WASHER
Hold the drive pulley face with special tool and remove
the drive pulley face nut, washer and drive pulley face.
TOOL:
Universal holder 07725-0030000
UNIVERSAL HOLDER
Slide the drive belt off from the drive pulley boss by
squeezing the drive belt.
DRIVE BELT
9-7
dummyhead

Remove the movable drive face assembly while holding
MOVABLE DRIVE FACE ASSEMBLY
the back of the face (ramp plate) and drive face boss.
INSTALLATION
Clean any oil and grease from the drive face and the
drive belt.
Be careful not to get Install the movable drive face assembly onto the
the movable drive crankshaft until it is fully seated while holding the ramp
face disassembled. plate.
RAMP PLATE
Compress the driven face spring by squeezing the drive

belt until there is enough slack to install the drive belt to DRIVE BELT
the drive pulley boss.
Set the drive belt onto the drive pulley boss by

squeezing it to obtain the clearance between the belt DRIVE BELT
and boss.
BOSS
Install the drive pulley face and make sure that the drive
pulley face is fully seated on the drive pulley boss. DRIVE PULLEY DRIVE
FACE PULLEY
BOSS
Fully seated
9-8
dummyhead

Install the washer.
WASHER
Apply engine oil to the drive pulley face nut threads and
seating surface then install it.
NUT
Hold the drive pulley face with the special tool and
tighten the nut to the specified torque. NUT UNIVERSAL HOLDER
TOOL:

Install the left crankcase cover (page 9-5)
DRIVE PULLEY FACE
– Drive face boss
– Ramp plate
– Slide pieces
– Weight rollers
• Clean any oil and grease from the weight rollers and movable drive face.
SLIDE PIECES
MOVABLE DRIVE FACE
RAMP PLATE
DRIVE FACE
BOSS
Left crankcase WEIGHT ROLLERS

cover side
9-9
dummyhead

INSPECTION
WEIGHT ROLLER
Check each roller for wear or damage.
Measure the weight roller O.D.
MOVABLE DRIVE FACE BOSS

Check the drive face boss for wear or damage.
Measure the drive face boss O.D.
MOVABLE DRIVE FACE

Check the movable drive face for scratches, scores or
damage.
Measure the drive face bushing I.D.
9-10
dummyhead

CLUTCH/DRIVEN PULLEY
REMOVAL
Hold the clutch outer with the special tool and remove
the nut. NUT/WASHER
TOOL:
Flywheel holder 07725-0040001
Remove the washer and clutch outer.
FLYWHEEL HOLDER CLUTCH OUTER
Hold the clutch/driven pulley assembly and compress

MOVABLE DRIVEN FACE
the driven face spring fully by turning the movable
driven face clockwise.
CLUTCH/DRIVEN PULLEY ASSEMBLY
Remove the clutch/driven pulley assembly from the

drive belt by holding the movable driven face. CLUTCH/DRIVEN PULLEY ASSEMBLY
INSTALLATION
Hold the clutch/driven pulley assembly and compress
the driven face spring fully by turning movable driven
face clockwise.
Set the drive belt onto the pulley groove while holding
the movable driven face.
Install the clutch/driven pulley assembly onto the

driveshaft.
CLUTCH/DRIVEN PULLEY ASSEMBLY
9-11
dummyhead

Clean any oil and grease from the clutch outer surface.
SPLINES
Degrease the driveshaft threads and splines, being
careful not to remove grease from driven pulley inside.
Install the clutch outer while aligning its splines with
driveshaft splines.
Degrease CLUTCH OUTER
Install the washer and clutch outer nut.

CLUTCH OUTER FLYWHEEL HOLDER
Hold the clutch outer with the special tool and tighten
the clutch outer nut to the specified torque.
TOOL:
Flywheel holder 07725-0040001
NUT/WASHER
DISASSEMBLY
Set the clutch spring compressor onto the clutch/driven
pulley by aligning the bosses of the compressor with the CLUTCH/DRIVEN CLUTCH SPRING
holes on the clutch. PULLEY COMPRESSOR
TOOL:
Clutch spring compressor 07LME-GZ40200
To prevent loss of Hold the clutch/driven pulley by turning the clutch spring
tension, do not compressor clockwise.
compress the clutch
spring more than
necessary.
Hold the clutch spring compressor in a vise.

SOCKET WRENCH
Remove the clutch/driven pulley nut using the special
tool.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
CLUTCH/DRIVEN
PULLEY NUT
9-12
dummyhead

Loosen the clutch spring compressor gradually and
remove the following: CLUTCH ASSEMBLY
– Clutch assembly SPRING SEAT

– Spring seat
– Driven face spring
– Driven pulley assembly
DRIVEN PULLEY
ASSEMBLY
DRIVEN FACE
SPRING
CLUTCH
Remove the three E-clips and plate.
E-CLIPS
Remove the clutch shoes from the drive plate.
Remove the clutch shoe springs from the clutch shoes.
Remove the damper rubbers from the drive plate.
PLATE
CLUTCH
SPRINGS SHOES
DAMPER RUBBERS DRIVE PLATE
9-13
dummyhead

DRIVEN PULLEY
Remove the seal collar.
SEAL COLLAR
Remove the guide pins and guide rollers from the
driven face.
Remove the movable driven face from the driven face.
Remove the O-rings and oil seals from the movable
driven face.
O-RINGS
MOVABLE
DRIVEN FACE
OIL SEALS
GUIDE PINS
GUIDE
ROLLERS
DRIVEN FACE
ASSEMBLY
DRIVEN FACE GUIDE PINS
OIL SEALS
GUIDE ROLLERS
O-RINGS
SEAL COLLAR
DRIVEN FACE SPRING
MOVABLE DRIVEN FACE

SPRING SEAT
PLATE
E-CLIPS
CLUTCH SHOES
SPRINGS
CLUTCH/DRIVEN PULLEY NUT
54 N·m (5.5 kgf·m, 40 lbf·ft) DRIVE PLATE DAMPER RUBBERS
9-14
dummyhead

DRIVEN PULLEY
Apply grease to new oil seal lips and install them into
the movable driven face.
O-RINGS
Coat new O-rings with engine oil and install them into OIL SEALS
the movable driven face grooves.
Clean any oil and grease from the pulley face.

MOVABLE DRIVEN FACE GUIDE
Install the movable driven face onto the driven face. ROLLERS/PINS
Install the guide rollers and guide pins.
Apply 2.0 – 2.5 g of grease (Shell ALVANIA R3 or
IDEMITSU AUTOREX B or SHIN-NIHON POWERNOC
WB3 or equivalent) to each guide groove.
DRIVEN FACE
Install the seal collar to the driven pulley.

SEAL COLLAR
CLUTCH
Install the damper rubbers onto the drive plate.
DRIVE PLATE
DAMPER RUBBERS
9-15
dummyhead

Install the shoe springs onto the clutch shoes as shown.
SPRING
Install the clutch shoes onto the drive plate by aligning
the damper rubbers.
CLUTCH SHOE
DRIVE PLATE
Install the plate to the clutch shoes assembly.

PLATE E-CLIP
Press the plate and install new E-clips into the grooves
on the drive plate pivot.
GROOVE
Assemble the following:
CLUTCH ASSEMBLY
– Driven pulley assembly
– Driven face spring SPRING SEAT
– Spring seat
– Clutch assembly
DRIVEN PULLEY
ASSEMBLY
DRIVEN FACE
SPRING
Set the clutch spring compressor over the clutch/driven Align (BOSSES/
pulley assembly aligning the bosses of the compressor
HOLES)
with the holes of the clutch.
TOOL:
Clutch spring compressor 07LME-GZ40200
To prevent loss of Compress the driven face spring while aligning the cut-
tension, do not out of the pulley nut threads with the drive plate hole
compress the clutch and install the clutch/driven pulley nut.
spring more than
necessary.
CLUTCH SPRING Align (CUT-OUT/

COMPRESSOR PLATE HOLE)
9-16
dummyhead

Hold the spring compressor in a vice.
SOCKET WRENCH
Tighten the clutch/driven pulley nut to the specified
torque using the socket wrench.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100

Remove the spring compressor from the clutch/driven
pulley assembly.
CLUTCH/DRIVEN
PULLEY NUT
INSPECTION
CLUTCH OUTER
Check the clutch outer for wear or damage.
Measure the clutch outer I.D.
DRIVEN FACE SPRING

Measure the driven face spring free length.
SERVICE LIMIT: 113 mm (4.4 in)
DRIVEN FACE
Check the driven face for scratches, scoring or
damage.
Measure the driven face boss O.D.
9-17
dummyhead

MOVABLE DRIVEN FACE
Check the movable driven face for scratches, scoring or
damage.
Check the guide grooves for stepped wear or damage.
Measure the movable driven face I.D.
DRIVEN FACE BEARING

REPLACEMENT
Remove the driven face needle bearing using the
special tools. BEARING REMOVER
TOOLS: FORK SEAL DRIVER

Bearing remover, 20 mm 07931-MA70000 ATTACHMENT
Fork seal driver attachment 07747-0010400
NEEDLE BEARING
Remove the snap ring and drive the ball bearing out of
the driven face. BALL BEARING
SNAP RING
Pack new ball bearing with grease.

Press the ball bearing into the driven face squarely with
its marked side facing down until it is fully seated, using BALL BEARING
the special tools.
DRIVER
TOOLS:
Driver 07749-0010000
Pilot, 28 mm 07746-0041100
Install the snap ring into the groove in the driven face
securely.
Apply 7.0 – 8.0 g of grease (Shell ALVANIA R3 or
IDEMITSU AUTOREX B or SHIN-NIHON POWERNOC
WB3 or equivalent) to the driven face inner surface. PILOT SNAP RING
9-18
dummyhead

Apply grease to a new needle bearing.
DRIVER
Press the needle bearing into the driven face squarely
with its marked side facing up until it is flush with the NEEDLE BEARING
driven face surface, using the special tools.
ATTACHMENT
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746-0040500
PILOT
KICKSTARTER
REMOVAL
BOLT
– Clutch/driven pulley (page 9-11)
Remove the bolt and the spring holder.
HOLDER
Unhook the return spring from the pins on the

crankcase and kickstarter spindle. PIN
Remove the kickstarter spindle and return spring.
SPINDLE PIN RETURN SPRING
Remove the spindle bushing and idle gear assembly.

BUSHING
IDLE GEAR ASSEMBLY
9-19
dummyhead

SPRING IDLE GEAR PIN
– Pin
– Washer
– Shaft
– Spring
– Friction spring SHAFT
INSTALLATION
Apply grease to the sliding surface of shaft and friction WASHER
spring.
Install the friction spring, spring and shaft to the idle
gear. FRICTION SPRING
Install the washer and pin to the shaft.
Apply grease to the kickstarter spindle bushing and
friction spring sliding area.
Install the idle gear assembly into the left crankcase,
aligning the pin with the groove and the friction spring IDLE GEAR
with the groove. ASSEMBLY
Align BUSHING
Install the spindle bushing.
Align
Install the spindle into the left crankcase, aligning the

marks on the driven gear and spindle. Align
SPINDLE
9-20
dummyhead

Hook the short end of the return spring to the spindle
pin. PIN
Hook the long end of the return spring to the crankcase
pin.
SPINDLE PIN RETURN SPRING
Install the bolt and spring holder and tighten it.

BOLT
HOLDER
INSPECTION
Replace the kickstarter spindle bushing if it is damaged
or worn. SPINDLE BUSHING
Inspect the following:

SPINDLE GEAR TEETH
– Spindle for wear, damage, or bending
– Gear teeth for wear or damage
– Return spring for weakness or damage
RETURN SPRING
9-21
dummyhead

Inspect the following:
IDLE GEAR
– Idle gear for wear or damage SPRING
– Friction spring for weakness or damage
– Spring for weakness or damage
– Shaft for wear or damage
SHAFT
FRICTION SPRING
9-22
dummytext
10. FINAL REDUCTION
COMPONENT LOCATION ··························10-2 FINAL REDUCTION CASE ASSEMBLY ···· 10-4
SERVICE INFORMATION ···························10-2 FINAL REDUCTION INSPECTION ············· 10-5
TROUBLESHOOTING·································10-2 FINAL REDUCTION BEARING

REPLACEMENT ········································· 10-7 10
SEPARATION··············································10-3
10-1
dummyhead
FINAL REDUCTION
COMPONENT LOCATION
FINAL REDUCTION
SERVICE INFORMATION
GENERAL
• Refer to page 3-9 for final reduction oil inspection and change.
• These services can be done with the engine installed in the frame.
• When installing the driveshaft, be sure to use the special tools; position the special tools against the bearing inner race and pull
the driveshaft into the bearing until it is fully seated.
TROUBLESHOOTING
Engine does start but scooter won’t move
• Damaged final reduction
• Seized final reduction
• Faulty drive pulley (page 9-7)
• Faulty driven pulley/clutch (page 9-11)
Abnormal noise
• Worn, seized or chipped gears
• Worn or damaged final reduction bearing
Oil leak
• Oil level too high
• Worn or damaged oil seal
• Cracked crankcase and/or final reduction case
10-2
dummyhead
FINAL REDUCTION
SEPARATION
• The final reduction can be serviced with the engine
installed in the frame.
Drain the final reduction oil (page 3-9)
Remove the following: BOLTS

– Rear wheel (page 14-4)
– Rear brake shoes (page 15-24)
Release the breather hose from the clamp.
Remove the final reduction case bolts and the clamps
from left crankcase.
BREATHER HOSE CLAMPS
Remove the final reduction case.

FINAL REDUCTION CASE DOWEL PINS
Remove the dowel pins and gasket.
GASKET
Remove the counter gear, countershaft and final gear

shaft.
COUNTER GEAR
FINAL GEAR SHAFT COUNTERSHAFT
10-3
dummyhead
FINAL REDUCTION
FINAL REDUCTION CASE ASSEMBLY
Be careful not to Clean the inside and mating surface of the left
damage the final crankcase and final reduction case. MATING SURFACE
reduction case Check for cracks or other damage.
mating surface.
Remove any roughness or irregularities with an oil
stone.
MATING SURFACE
Apply engine oil to each gear teeth and each bearing

sliding area of the shafts.
Install the final gear shaft into the left crankcase.
Install the countershaft into the counter gear while COUNTER GEAR
aligning the countershaft splines with the counter gear
splines and install them to the left crankcase.
FINAL GEAR COUNTER

SHAFT SHAFT
10-4
dummyhead
FINAL REDUCTION
Install a new gasket and dowel pins to the left
crankcase. FINAL REDUCTION CASE DOWEL PINS
Install the final reduction case.
GASKET
Install the clamp and tighten the final reduction case

bolts in a crisscross pattern in two or three steps. BOLTS
Set the breather hose to the clamp.
– Rear brake shoes (page 15-24)
– Rear wheel (page 14-4)
Fill the final reduction case with recommended oil (page
3-9).
BREATHER HOSE CLAMPS
FINAL REDUCTION INSPECTION

BEARING
LEFT CRANKCASE
Check each bearing for wear or damage.
FINAL GEAR DRIVESHAFT
Turn the inner race of the countershaft and final gear SHAFT BEARING
shaft bearings with your finger. The bearing should turn BEARING
smoothly and quietly. Also check that the bearing outer
race fits tightly in the crankcase.
Replace the bearings if they do not turn smoothly,
quietly, or if they fit loosely on the crankcase.
Turn the driveshaft with your hand. The shaft should
turn smoothly and quietly. Also check that the bearing
outer race fits tightly in the crankcase and the bearing
inner race fits tightly on the driveshaft.
Replace the bearing if it does not turn smoothly, quietly,
or if it fits loosely on the crankcase and driveshaft.
COUNTERSHAFT BEARING

Check the final reduction case bearings and final gear
DRIVESHAFT BEARING FINAL GEAR
shaft oil seal for wear or damage.
SHAFT BEARING
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the final
reduction case.
quietly, or if they fit loosely on the final reduction case.
OIL SEAL
10-5
dummyhead
FINAL REDUCTION
GEAR/SHAFT
DRIVESHAFT
Check the driveshaft for bend, wear or damage.
Check the drive gear for wear or damage. DRIVESHAFT
DRIVE GEAR
COUNTERSHAFT/COUNTER GEAR/FINAL GEAR

SHAFT
Check the countershaft, counter gear and final gear
FINAL GEAR SHAFT COUNTERSHAFT
shaft for wear or damage.
COUNTER GEAR
10-6
dummyhead
FINAL REDUCTION
FINAL REDUCTION BEARING
REPLACEMENT
DRIVESHAFT
BEARING (No.6204)
DRIVESHAFT
OIL SEAL BEARING (No.6301)
(20 x 32 x 6)
COUNTERSHAFT
BEARING (No.6201)
OIL SEAL
(27 x 42 x 7)
COUNTERSHAFT
BEARING (No.6202)
FINAL GEAR SHAFT

BEARING (No.6203)
FINAL GEAR SHAFT
BEARING (No.6004UU)

Remove the final gear shaft oil seal.
FINAL GEAR SHAFT OIL SEAL
Be careful not to Remove the final gear shaft bearing.

DRIVESHAFT FINAL GEAR SHAFT
damage the final
Remove the driveshaft and countershaft bearings using BEARING SHAFT BEARING
reduction case
the special tools.
mating surface.
TOOLS: WEIGHT
Bearing remover head, 12 mm 07936-1660110
Bearing remover shaft, 12 mm 07936-1660120
Remover weight 07741-0010201
COUNTERSHAFT
BEARING HEAD BEARING
10-7
dummyhead
FINAL REDUCTION
Apply engine oil to the bearing cavity.
DRIVER
Drive a new driveshaft bearing into the final reduction
case squarely with its marked side facing up until it is DRIVESHAFT
ATTACHMENT
fully seated, using the special tools. BEARING
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 12 mm 07746-0040200
Drive a new countershaft bearing into the final reduction
case squarely until it is fully seated, using the special
tools.
TOOLS: BEARING PILOT
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200

DRIVER
Press a new driveshaft bearing into the final reduction
case squarely with its marked side facing up until it is FINAL GEAR
fully seated, using the special tools and hydraulic press. SHAFT BEARING
TOOLS:
Driver 07749-0010000
Attachment, 40 x 42 mm 07746-0010900
Pilot, 20 mm 07746-0040500
ATTACHMENT BEARING PILOT
Apply engine oil to a new final gear shaft oil seal lip.
Install the final gear shaft oil seal with the flat side DRIVER
facing the rear wheel side until it is flush with the final OIL SEAL
reduction case, using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 40 x 42 mm 07746-0010900
ATTACHMENT OIL SEAL
LEFT CRANKCASE BEARING

Be careful not to Remove the countershaft and final gear shaft bearings SHAFT
FINAL GEAR
damage the final using the special tools.
SHAFT BEARING
reduction case
mating surface. TOOLS:
Countershaft bearing: WEIGHT
Bearing remover head, 15 mm 07936-KC10200
Bearing remover shaft, 15 mm 07936-KC10100
Final gear shaft bearing:
Bearing remover, 17 mm 07936-3710300
Bearing remover handle 07936-3710100
COUNTERSHAFT
HEAD BEARING
BEARING
10-8
dummyhead
FINAL REDUCTION
DRIVER ATTACHMENT
Drive a new countershaft bearing into the left crankcase
squarely with its marked side facing up until it is fully FINAL GEAR
seated, using the special tools. SHAFT BEARING
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 15 mm 07746-0040300
Drive a new final gear shaft bearings into the left
crankcase squarely until it is fully seated, using the
special tools.
TOOLS: BEARING PILOT
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 17 mm 07746-0040400
DRIVESHAFT BEARING
Remove the driveshaft using the special tool.
TOOL:
Case puller 07SMC-0010001
DRIVESHAFT CASE PULLER
CASE PULLER
DRIVESHAFT
10-9
dummyhead
FINAL REDUCTION
Remove the driveshaft bearing using a hydraulic press.
DRIVESHAFT
– If the driveshaft bearing remains in the left
crankcase, remove it to the right side.
DRIVESHAFT BEARING
- If the driveshaft bearing

remains in the left crankcase:
DRIVESHAFT
BEARING
Remove the driveshaft oil seal from the left crankcase.

DRIVESHAFT OIL SEAL
Apply engine oil to the bearing cavity. DRIVESHAFT DRIVER

Drive a new driveshaft bearing into the left crankcase BEARING
squarely with its marked side facing up until it is fully
seated, using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
ATTACHMENT BEARING PILOT
10-10
dummyhead
FINAL REDUCTION
Install the driveshaft into the bearing.
Position the assembly collar on the driveshaft bearing ASSEMBLY COLLAR DRIVESHAFT
inner race and pull the drive shaft into the bearing until it
is fully seated.
TOOLS:
Assembly shaft 07965-1660200
Assembly collar 07965-GM00100
Assembly collar attachment 07965-GM00200 ASSEMBLY
SHAFT
ASSEMBLY COLLAR
ATTACHMENT
DRIVESHAFT ASSEMBLY
BEARING COLLAR
INNER ATTACHMENT
RACE
ASSEMBLY
COLLAR
ASSEMBLY SHAFT
DRIVESHAFT BEARING
Apply engine oil to a new driveshaft oil seal lip.

OIL SEAL ASSEMBLY COLLAR
Do not insert the oil Install the new driveshaft oil seal into the left crankcase
seal too far. with its marked side facing up until the depth from the
end surface is 0 - 0.5 mm (0 - 0.02 in), using the special
tools.
TOOLS:
Assembly shaft 07965-1660200
Assembly collar 07965-GM00100
Assembly collar attachment 07965-GM00200 ASSEMBLY
SHAFT
ASSEMBLY COLLAR
ATTACHMENT
ASSEMBLY COLLAR ASSEMBLY

ATTACHMENT COLLAR
ASSEMBLY SHAFT
OIL SEAL
0 - 0.5 mm
(0 - 0.02 in)
10-11
dummyhead
MEMO
dummytext
11. ALTERNATOR/STARTER CLUTCH
COMPONENT LOCATION ··························11-2 RIGHT CRANKCASE COVER ···················· 11-6
SERVICE INFORMATION ···························11-2 STARTER IDLE GEAR ······························· 11-8
TROUBLESHOOTING·································11-2 STARTER CLUTCH ···································· 11-9
FLYWHEEL/STATOR··································11-3 11
11-1
dummyhead
COMPONENT LOCATION
98 N·m (10 kgf·m, 72 lbf·ft)
14 N·m (1.4 kgf·m, 10 lbf·ft)
6 N·m (0.6 kgf·m, 4.4 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)
8 N·m (0.8 kgf·m, 5.9 lbf·ft)
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of the flywheel, alternator/starter clutch and ignition pulse generator.
• These service can be done with the engine installed in the frame.
• Refer to page 16-6 for alternator inspection.
• Refer to page 17-5 for ignition pulse generator inspection.
TROUBLESHOOTING
Starter motor turns, but engine does not start
• Faulty starter clutch
• Damaged starter reduction gear
11-2
dummyhead
FLYWHEEL/STATOR
REMOVAL
WIRE BAND
– Right side cover (page 2-5) WIRE CLAMP
– Luggage box (page 2-4) 3P CONNECTOR
Pull the dust cover off and disconnect the alternator/
ignition pulse generator 3P connector.
Release the alternator wire from the wire clamp, wire
band and guides.
ALTERNATOR WIRE BAND

WIRE WIRE GUIDES
Remove the two bolts, two special bolts and cooling fan
SPECIAL BOLTS BOLTS
cover.
COOLING FAN COVER
Remove the four bolts and cooling fan.

COOLING FAN
BOLTS
Hold the flywheel with the special tool and loosen the
flywheel nut. NUT/WASHER
TOOL:
Remove the flywheel nut and washer.
UNIVERSAL HOLDER
11-3
dummyhead
Remove the flywheel using the special tool.
FLYWHEEL
TOOL:
Flywheel puller 07733-0010000
FLYWHEEL PULLER
Remove the two bolts and wire holder.

WIRE HOLDER
BOLTS
Be careful not to Hold the stator and the ignition pulse generator, then
damage the wire. remove the mounting bolts.
Remove the stator, ignition pulse generator, wires and STATOR GROMMET
grommet as assembly from the right crankcase cover. MOUNTING
BOLTS
WIRE
INSTALLATION
Apply liquid sealant to the alternator wire grommet.
Route the wire Set the wire, wire grommet, stator and ignition pulse
properly (page 1- generator to the right crankcase cover securely.
13).
Install and tighten the stator mounting bolts to the
specified torque.
Install and tighten the ignition pulse generator mounting
bolts to the specified torque.
TORQUE: 6 N·m (0.6 kgf·m, 4.4 lbf·ft) STATOR
IGNITION PULSE
IGNITION PULSE GENERATOR
GENERATOR
MOUNTING BOLTS
11-4
dummyhead
Install the wire holder and the two bolts.
WIRE HOLDER
BOLTS
Clean any grease from the crankshaft and flywheel

tapered area. Align (KEY WAY/WOODRUFF KEY)
Install the flywheel onto the crankshaft by aligning the
key way in the flywheel with the key on the crankshaft.
Install the washer and flywheel nut.

Hold the flywheel with the special tool and tighten the NUT/WASHER
nut to the specified torque.
TOOL:
UNIVERSAL HOLDER
Install the cooling fan and tighten the bolts.

COOLING FAN
BOLTS
11-5
dummyhead
Install the cooling fan cover and tighten the bolts.
SPECIAL BOLTS BOLTS
Tighten the special bolts to the specified torque.
COOLING FAN COVER
Route the wire Set the alternator wire to the wire clamp, wire bands
properly (page 1- and wire guides. WIRE BAND
13). WIRE CLAMP
Connect the alternator/ignition pulse generator 3P 3P CONNECTOR
connector and pull back the dust cover.
– Right side cover (page 2-5)
ALTERNATOR WIRE BAND

WIRE WIRE GUIDES
RIGHT CRANKCASE COVER

REMOVAL
Remove the flywheel/stator(page 11-3).
WOODRUFF KEY
Remove the woodruff key.
Remove the bolts, band stay and ground cable.

BAND STAY/GROUND CABLE
Remove the right crankcase cover. BOLTS
COVER
11-6
dummyhead
Remove the two dowel pins and gasket.
GASKET
INSTALLATION
Install a new gasket and two dowel pins.
DOWEL PINS
Install the right crankcase cover.

BAND STAY/GROUND CABLE
Install the band stay, ground cable and bolts to the right BOLTS
crankcase cover, then tighten the bolts in a crisscross
pattern in 2 or 3 steps.
COVER
Install the woodruff key into the crankshaft key groove.

WOODRUFF KEY
Install the flywheel/stator (page 11-4).
OIL SEAL REPLACEMENT

Remove the right crankcase cover (page 11-6).
Remove the oil seal. OIL SEAL
11-7
dummyhead
Install a new oil seal using the special tool.
DRIVER
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
Pilot, 20 mm 07746-0040500
OIL SEAL
ATTACHMENT/PILOT
STARTER IDLE GEAR

REMOVAL
Remove the starter clutch (page 11-9).
Remove the shaft and starter idle gear. Align (MOTOR GEAR/IDLE GEAR)
INSTALLATION
Apply clean engine oil to the shaft and starter idle gear
teeth.
Install the shaft and install the starter idle gear by
aligning its teeth with the starter motor gear.
Install the starter clutch (page 11-9).
STARTER
SHAFT IDLE GEAR
INSPECTION
Check the starter idle gear teeth for wear or damage.
STARTER IDLE GEAR
11-8
dummyhead
STARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 11-6).
OIL PUMP COVER
Remove the two bolts and oil pump cover.
BOLTS
The starter clutch Hold the starter driven gear using the universal holder,
lock nut has left then remove the starter clutch lock nut using the lock NUT/WASHER
LOCK NUT WRENCH
hand threads. nut wrench.
TOOLS:
Lock nut wrench 07916-9690000
Remove the washer.
UNIVERSAL HOLDER
Remove the starter clutch/starter driven gear.

DRIVEN GEAR
INSTALLATION
Install the starter clutch/starter driven gear onto the
crankshaft.
STARTER CLUTCH
Install the washer.

LOCK NUT
Apply clean engine oil to the starter clutch lock nut NUT/WASHER WRENCH
threads and seating surface.
The starter clutch Hold the starter driven gear using the universal holder
lock nut has left then tighten the starter clutch lock nut to the specified
hand threads. torque using the lock nut wrench.
TOOLS:
Lock nut wrench 07916-9690000
UNIVERSAL HOLDER
11-9
dummyhead
Install the oil pump cover and tighten the bolts to the
specified torque. OIL PUMP COVER

Install the right crankcase cover (page 11-7).
BOLTS
DISASSEMBLY
Remove the starter driven gear by turning it
counterclockwise. DRIVEN GEAR
Remove the needle bearing.

Remove the three socket bolts from the starter clutch.
NEEDLE BEARING
SOCKET BOLTS
Remove the starter clutch flange from the starter clutch

outer. CLUTCH FLANGE
STARTER CLUTCH OUTER
Remove the starter clutch rollers, plungers and springs

from the starter clutch outer. ROLLERS PLUNGERS
SPRINGS
11-10
dummyhead
ASSEMBLY
SOCKET BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft)
NEEDLE
BEARING
SPRING
PLUNGER
DRIVEN GEAR

ROLLER
STARTER CLUTCH FLANGE
Apply clean engine oil to the roller surface.

Install the starter clutch rollers, plungers and springs. ROLLERS PLUNGERS
SPRINGS
Install the starter clutch flange into the starter clutch

outer. CLUTCH FLANGE
11-11
dummyhead
Apply locking agent to the socket bolt threads.
Install and tighten the socket bolts to the specified
torque.
SOCKET BOLTS
Apply clean engine oil to the starter driven gear teeth

and needle bearing. DRIVEN GEAR
Install the needle bearing.
NEEDLE
BEARING
Install the starter driven gear into the starter clutch by

turning it counterclockwise. DRIVEN GEAR
Check the operation of the starter clutch by turning the
driven gear.
Check that the starter driven gear turns
counterclockwise smoothly and does not turn
clockwise.
INSPECTION
STARTER DRIVEN GEAR
Check the starter driven gear for wear or damage.
Check the needle bearing for wear or damage.
DRIVEN GEAR NEEDLE BEARING
11-12
dummyhead
Check the starter clutch flange for wear or damage.

Check the starter clutch outer for wear or damage.
ROLLERS PLUNGERS
Check the starter clutch rollers, plungers and springs
for wear or damage.
SPRINGS
11-13
dummyhead
MEMO
dummytext
12. CRANKCASE/CRANKSHAFT
COMPONENT LOCATION ··························12-2 CRANKCASE ASSEMBLY ························· 12-6
SERVICE INFORMATION ···························12-3 RIGHT CRANKSHAFT BEARING

REPLACEMENT ········································· 12-8
TROUBLESHOOTING·································12-3
CRANKSHAFT INSPECTION ····················· 12-9
CRANKCASE SEPARATION······················12-4
12
12-1
dummyhead
COMPONENT LOCATION
12-2
dummyhead
SERVICE INFORMATION
GENERAL
• This section covers the crankcase separation to service the crankshaft.
• The following parts must be removed before separating the crankcase.
– Engine (page 6-3)
– Cylinder head/valves (page 7-6)
– Cylinder (page 8-3)
– Piston (page 8-4)
– Starter motor (page 18-4)
– Flywheel/stator (page 11-3)
– Starter idle gear (page 11-8)
– Starter clutch (page 11-9)
– Oil pump drive chain (page 4-4)
• In addition to the parts listed above, remove the following parts when the left crankcase half must be replaced.
– Final reduction (page 10-3)
• Be careful not to damage the crankcase mating surfaces when separating and assembling the crankcase halves.
• Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
TROUBLESHOOTING
Abnormal noise
• Worn crankshaft bearing
• Worn connecting rod big end bearing
• Worn connecting rod small end (page 8-8)
12-3
dummyhead
CRANKCASE SEPARATION
Refer to Service Information (page 12-3) for removal of
necessary parts before separating the crankcase. SPROCKET
Remove the kickstarter driven sprocket using the
special tool.
TOOL:
Flywheel puller set 07RMC-KCW0100
PULLER SET
Remove the cam chain cover nuts.
NUTS
Screw the 6 mm bolts into the threaded hole on the cam

chain cover. CAM CHAIN COVER
6 mm BOLTS
Remove the cam chain cover from the left crankcase.

CAM CHAIN COVER O-RING
Remove the oil seal and O-ring from the cam chain
cover.
OIL SEAL
12-4
dummyhead
Remove the O-rings from the left crankcase.
Remove the cam chain tensioner slider and cam chain. CAM CHAIN TENSIONER SLIDER
O-RINGS
CAM CHAIN
Remove the crankcase bolts from the right crankcase.
BOLTS
Be careful not to Place the crankcase with the left crankcase facing
damage the down and separate the left and right crankcase.
crankcase mating
surface.
RIGHT CRANKCASE
Remove the gasket and dowel pins from the left

crankcase. CRANKSHAFT GASKET
Remove the crankshaft.
Clean any gasket from the crankcase mating surface.
DOWEL PINS
12-5
dummyhead
CRANKCASE ASSEMBLY
• Be careful not to damage the crankcase mating
surface.
Clean the insides and mating surface of the
crankcases. MATING SURFACE
Check for cracks or other damage.
Remove any roughness or irregularities with an oil
stone.
MATING SURFACE
Apply 3 cc minimum of engine oil to the connecting rod

big end bearing. CRANKSHAFT GASKET
Apply 2 cc minimum of engine oil to crankshaft bearing.
Install the crankshaft to the left crankcase.
Install the dowel pins and new gasket to the left
crankcase.
DOWEL PINS
Assemble the left and right crankcase.
RIGHT CRANKCASE
12-6
dummyhead
Install the crankcase bolts and tighten them.
BOLTS
Install the cam chain tensioner slider to the left

crankcase. CAM CHAIN TENSIONER SLIDER
Apply engine oil to the timing sprocket and cam chain.
Install the cam chain to the timing sprocket.
Coat the new O-rings with engine oil and install them O-RINGS
into the left crankcase.
CAM CHAIN
Apply engine oil to a new oil seal lip.

Install the new oil seal lip to the cam chain cover until it ATTACHMENT DRIVER
is flush with the cam chain cover, using the special tool.
TOOLS:
Driver 07749-0010000
Attachment, 28 x 30 mm 07946-1870100
OIL SEAL
Coat a new O-ring with engine oil and install it into the
CAM CHAIN COVER
groove on the cam chain cover.
Install the cam chain cover to the left crankcase.
Remove the 6 mm bolts.
6 mm
BOLTS
O-RING
12-7
dummyhead
Install and tighten the cam chain cover nuts to the
specified torque.
NUTS
Clean any grease from the kickstarter driven sprocket

and the crank shaft tapered area. SPROCKET
Install the kickstarter driven sprocket to the crankshaft.
Install the removed parts (page 12-3).
RIGHT CRANKSHAFT BEARING

REPLACEMENT
Separate the crankcase (page 12-4).
NUTS
Remove the oil path plate nuts.
Remove the oil path plate and O-ring.

OIL PATH PLATE
Remove the right crankshaft bearing. BEARING
O-RING
12-8
dummyhead
Apply 2 cc minimum of engine oil to new right
crankshaft bearing. DRIVER
Press the right crankshaft bearing into the right
ATTACHMENT
crankcase squarely with its marked side facing up until
it is fully seated, using the special tools and hydraulic
press.
TOOLS:
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 25 mm 07746-0040600
BEARING PILOT
OIL PATH PLATE
groove on the right crankcase.
Install the oil path plate.
O-RING
Install and tighten the oil path plate nuts.

NUTS
Assemble the left and right crankcase (page 12-6).
CRANKSHAFT INSPECTION
Measure the connecting rod big end side clearance with
a feeler gauge.
12-9
dummyhead
Set the crankshaft on V-blocks and measure the
connecting rod big end radial clearance.
Set the crankshaft on a V-blocks and measure the

runout using a dial indicator.
Actual runout is 1/2 of total indicator reading.
70 mm 90 mm
(2.8 in) (3.5 in)
If the timing Check the timing sprocket teeth for wear or damage.
sprocket teeth are BEARING
Turn the outer race of the crankshaft bearing with your
worn or damaged,
finger. The bearing should turn smoothly and quietly.
check the cam
Also check that the bearing inner race fits tightly on the
chain, tensioner
crankshaft.
and cam sprocket.
quietly, or if they fit loosely on the crankshaft.
TIMING SPROCKET
12-10
dummytext
13. FRONT WHEEL/SUSPENSION/STEERING
COMPONENT LOCATION ··························13-2 FORK························································· 13-14
SERVICE INFORMATION ···························13-4 HANDLEBAR ············································ 13-22
TROUBLESHOOTING·································13-4 STEERING STEM ····································· 13-27
FRONT WHEEL···········································13-5
13
13-1
dummyhead
COMPONENT LOCATION
MX TYPE:
49 N·m (5.0 kgf·m, 36 lbf·ft)
49 N·m (5.0 kgf·m, 36 lbf·ft)
2 N·m (0.2 kgf·m, 1.5 lbf·ft)

59 N·m (6.0 kgf·m, 44 lbf·ft)
13-2
dummyhead
EXCEPT MX TYPE:
12 N·m (1.2 kgf·m, 9 lbf·ft)
49 N·m (5.0 kgf·m, 36 lbf·ft)
49 N·m (5.0 kgf·m, 36 lbf·ft)
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
30 N·m (3.1 kgf·m, 22 lbf·ft)
59 N·m (6.0 kgf·m, 44 lbf·ft)
13-3
dummyhead
SERVICE INFORMATION
GENERAL
• This section covers the front wheel, fork, handlebar and steering stem.
• When servicing the front wheel, fork or steering stem, support the scooter using a jack or other support.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with high
quality brake degreasing agent.
• After the front wheel installation, check the brake operation (page 3-11).
• For brake system service, refer to the following:
– Brake fluid replacement/air bleeding (page 15-4)
– Brake pad/disc (page 15-6)
– Front brake master cylinder (page 15-8)
– Brake equalizer (page 15-17)
– Front brake caliper (page 15-13)
– Front drum brake (page 15-21)
• Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE".
TROUBLESHOOTING
Hard steering
• Insufficient tire pressure
• Faulty tire
• Steering stem adjusting nut too tight
• Faulty steering head bearing
• Faulty steering head bearing race
• Bent steering stem
Steers to one side or does not track straight
• Bent front axle
• Wheel installed incorrectly
• Worn or damaged front wheel bearings
• Bent fork
• Worn or damaged engine mounting bushings (page 6-12)
• Bent frame
• Faulty steering head bearing
Front wheel wobbles
• Loose front axle fasteners
• Bent rim
• Worn or damaged front wheel bearings
Front wheel turns hard
• Front brake drag
• Bent front axle
• Faulty front wheel bearings
Soft suspension
• Low tire pressure
• Deteriorated fork fluid
• Incorrect fork fluid viscosity
• Insufficient fluid in fork
• Weak fork spring
Hard suspension
• High tire pressure
• Too much fluid in fork
• Incorrect fork fluid viscosity
• Bent fork pipes
• Clogged fork fluid passage
Suspension noisy
• Worn fork slider guide busing
• Insufficient fluid in fork
• Loose fork fasteners
13-4
dummyhead
FRONT WHEEL
EXCEPT MX TYPE
REMOVAL
Loosen the front axle nut.
SPEEDOMETER CABLE
Remove the screw and disconnect the speedometer
cable.
Support the scooter securely using a jack or other
support and raise the front wheel off the ground.
Remove the front axle nut.
Do not operate the Remove the front axle and the front wheel.
brake lever after
removing the front
wheel.
AXLE NUT SCREW
Remove the speedometer gearbox from the right wheel

hub. SPEEDOMETER GEARBOX
Remove the side collar from the left wheel hub.

SIDE COLLAR
INSTALLATION
Apply grease to the dust seal lips.
Install the side collar to the left wheel hub.
DUST SEAL
Apply grease to the dust seal lips. SPEEDOMETER

Apply 1.0 – 1.5 g of grease to the speedometer gear GEARBOX
teeth.
Apply grease to the speedometer gear rolling contact
area.
Install the speedometer gearbox onto the right wheel
hub by aligning the gearbox grooves with the retainer
tabs.
Align
13-5
dummyhead
Be careful not to Install the front wheel by seating the fork tab on the
damage the brake speedometer gearbox tab so that the brake disc is AXLE BOLT
pads. positioned between the brake pads.
Install the front axle bolt from the right side.
Seat
Install the axle nut and tighten it to the specified torque.
AXLE NUT
Coat a new O-ring with grease and install it into the

groove on the speedometer cable. SPEEDOMETER CABLE
Connect the speedometer cable while aligning the tab O-RING

of the speedometer gearbox with the slot of the
speedometer cable.
Install the speedometer cable mounting screw and
Turn the front wheel by hand and check that the
speedometer moves.
Align SCREW
MX TYPE
REMOVAL
Remove the front brake adjusting nut, brake cable and
brake arm joint pin. JOINT PIN
ADJUSTING NUT BRAKE CABLE
13-6
dummyhead
Remove the screw and pull out the speedometer cable
from the brake panel. SPEEDOMETER CABLE
SCREW
Loosen the front axle nut.

Support the scooter securely using a jack or other
support and raise the front wheel off the ground.
Remove the front axle nut.
Remove the front axle and front wheel.
AXLE NUT/AXLE
Remove the brake panel assembly from the left side of

the wheel hub. BRAKE PANEL
Remove the side collar from the right side of the wheel
hub. SIDE COLLAR
INSTALLATION
Install the side collar to the right wheel hub.
DUST SEAL
13-7
dummyhead
Do not get grease Install the brake panel assembly into the left wheel hub
on the brake drum by aligning the speedometer tabs with the hub grooves. BRAKE PANEL
and shoe linings.
Align
Set the front wheel between the fork legs while aligning
the brake panel groove with the boss on the left fork leg. Align
Install the front axle from right side.

Install the axle nut and tighten it to the specified torque.
FRONT AXLE AXLE NUT
Install the speedometer cable to the brake panel by

Insert SPEEDOMETER
inserting the speedometer gear tab to the speedometer
cable end groove. CABLE
Align the cable grommet groove with the screw hole on

the brake panel.
Install the speedometer cable mounting screw and
Turn the front wheel by hand and check that the
speedometer moves.
SCREW Align GROMMET
13-8
dummyhead
Install the front brake arm joint pin, brake cable and
brake adjusting nut. JOINT PIN
Adjust the brake lever freeplay and check the brake

operation (page 3-11).
ADJUSTING NUT BRAKE CABLE
DISASSEMBLY
EXCEPT MX TYPE
Remove the dust seal from the left wheel hub.
DUST SEAL
Remove the front brake disc socket bolts and brake
disc.
BRAKE DISC SOCKET BOLTS
Remove the dust seal from the right wheel hub.

DUST SEAL
MX TYPE
Remove the dust seal from the right wheel hub.
DUST SEAL
13-9
dummyhead
Do not reuse the Install the bearing remover head into the bearing.
old bearings. From the opposite side of the wheel, install the bearing
remover shaft and drive the bearing out of the wheel
hub. REMOVER HEAD REMOVER SHAFT
TOOLS:
Bearing remover shaft 07746-0050100
Bearing remover head, 12 mm 07746-0050300
Remove the distance collar and drive out the other
bearing.
REMOVER
BEARING HEAD
REMOVER
HEAD
BEARING
REMOVER SHAFT
ASSEMBLY
Except MX type:
DUST SEAL
DISTANCE COLLAR
DUST SEAL
BRAKE DISC
BEARING
(6201U)
BEARING
(6201U) SOCKET BOLTS
42 N·m (4.3 kgf·m, 31 lbf·ft)
13-10
dummyhead
MX type:
BEARING
(6201U)
DUST SEAL
BEARING
(6201U)
DISTANCE COLLAR
Pack the new bearing cavity with grease.

ATTACHMENT DRIVER
Do not reuse the old Drive a new left bearing squarely with its sealed side
bearings. facing out until it is fully seated, using the special tools.
TOOLS:
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
PILOT BEARING
Install the distance collar from right side of the wheel.

Except MX type shown:
Drive a new right bearing squarely with its sealed side
facing out until its inner race fully seated on distance
collar, using the special tools. DISTANCE
COLLAR
TOOLS: BEARING
Driver 07749-0010000
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
13-11
dummyhead
EXCEPT MX TYPE
Do not get grease Install the brake disc on the left wheel hub with the
on the brake disc or stamp mark facing up. STAMP MARK
stopping power will Install and tighten new front brake disc socket bolts to
be reduced. the specified torque.
BRAKE DISC SOCKET BOLTS
Install a new dust seal into the left wheel hub until it is
flush with the wheel hub.
DUST SEAL
Install a new dust seal into the right wheel hub until it is
fully seated.
Apply grease to the dust seal outer surface. DUST SEAL
MX TYPE
Install a new dust seal to the right wheel hub.
Apply grease to the right dust seal lips.
DUST SEAL
13-12
dummyhead
INSPECTION
AXLE
Place the axle in V-blocks and measure the runout.
Actual runout is 1/2 the total indicator reading.
AXLE
WHEEL BEARING
Turn the inner race of each bearing with your finger,
the bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
hub.
Replace the wheel Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly, quietly, or if they fit loosely in the hub.
WHEEL BEARING
WHEEL RIM
Check the rim runout by placing the wheel in a turning
stand. Except MX
Spin the wheel slowly and read the runout using a dial type shown:
indicator.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
13-13
dummyhead
FORK
REMOVAL
EXCEPT MX TYPE
Remove the front wheel (page 13-5).
Support the front Remove the brake caliper mounting bolts.
Remove the bolt and brake hose guide. UPPER FORK PINCH BOLT
brake caliper so it FORK CAP BOLT
does not hang from Remove the bolt and speedometer cable guide.
the brake hose.
Do not twist the
brake hose.
MX TYPE
LOWER FORK
PINCH BOLT
Remove the bolt and cable guide.
BOLT
If the fork will be disassembled, loosen the fork cap bolt,

but do not remove it yet.
BOLT
Remove the upper fork pinch bolt.
Hold the fork and loosen the lower fork pinch bolt.
Remove the fork from the steering stem.
CABLE
GUIDE
HOSE
GUIDE
FORK BOLTS
INSTALLATION
Install the fork into the steering stem.
Align the groove on the fork pipe with the upper fork UPPER FORK PINCH BOLT HOLE
pinch bolt hole on the stem.
Align the top end of the fork pipes with the upper
surface of the steering stem.
Align
BOLT HOLE GROOVE
13-14
dummyhead
Install the upper fork pinch bolt.
Tighten the upper/lower fork pinch bolts to the specified
torque.
UPPER FORK PINCH BOLT
FORK CAP BOLT
If the fork is disassembled, tighten the fork cap bolt to
the specified torque.
LOWER FORK
PINCH BOLT
EXCEPT MX TYPE
BOLT
Install new brake caliper mounting bolts to the specified
torque.
BOLT
Install the speedometer cable guide and tighten the
bolt.
Install the brake hose guide and tighten the bolt.
CABLE
Install the front wheel (page 13-5). GUIDE
MX TYPE
Install the cable guide and the cable. HOSE
Install the front wheel (page 13-7). GUIDE
FORK BOLTS
DISASSEMBLY
Hold the fork slider in a vise with a soft jaws or shop
towel. SOCKET BOLT
Remove the socket Loosen the fork socket bolt, but do not remove yet.
bolt/sealing washer
after draining the
fork fluid.
Remove the fork cap bolt and O-ring.

FORK CAP BOLT/O-RING
13-15
dummyhead
Remove the fork spring from the fork pipe.
FORK PIPE
Pour out the fork fluid by pumping the fork pipe several
times. FORK SPRING
Be careful not to Remove the dust seal from the fork slider.
scratch the fork DUST SEAL
slider.
Be careful not to Remove the oil seal stopper ring from the fork slider.
scratch the fork STOPPER RING
pipe.
Remove the socket bolt and sealing washer.
SOCKET BOLT
SEALING WASHER
13-16
dummyhead
Pull the fork pipe out from the fork slider and remove
the oil lock piece. OIL LOCK PIECE
FORK PIPE
Remove the fork piston and rebound spring from the

fork pipe. REBOUND SPRING
FORK PISTON
Remove the oil seal using the special tool.

OIL SEAL REMOVER
TOOL:
Oil seal remover 07748-0010001 or
equivalent
OIL SEAL
Remove the back-up ring from the fork slider.

BACK-UP RING
13-17
dummyhead
ASSEMBLY
DUST SEAL FORK PIPE
STOPPER RING FORK PISTON

FORK CAP BOLT
OIL SEAL
O-RING
BACK-UP RING
FORK SLIDER
FORK SPRING
SEALING WASHER
REBOUND SPRING
SOCKET BOLT
20 N·m (2.0 kgf·m, 15 lbf·ft) OIL LOCK PIECE
Before assembly, wash all parts with high flash point or

non-flammable solvent and wipe them dry. REBOUND SPRING
Install the rebound spring and fork piston into the fork
pipe.
FORK PISTON
Install the oil lock piece to the fork piston.

FORK PISTON OIL LOCK PIECE
Install the fork pipe into the fork slider.
FORK PIPE
13-18
dummyhead
Clean the socket bolt threads and apply locking agent
to the bolt threads.
Install the socket bolt with a new sealing washer into
the fork piston. SOCKET BOLT
SEALING WASHER
Hold the fork slider in a vise with soft jaws or a shop

towel. SOCKET BOLT
Tighten the fork socket bolt to the specified torque.

If the fork piston turns together with the socket bolt,
temporarily install the fork spring and fork cap bolt.
Install the back-up ring over the fork pipe and seat it on
the fork slider. BACK-UP RING
FORK SLIDER
Coat a new oil seal lip with fork fluid and install it into
FORK SEAL DRIVER BODY
the fork slider using the special tools until it is fully
seated.
TOOLS:
Fork seal driver body 07747-0010100
Fork seal driver attachment 07747-0010400
ATTACHMENT OIL SEAL
13-19
dummyhead
Be careful not to Install the stopper ring into the groove on the fork slider.
scratch the fork
pipe.
STOPPER RING
Apply fork fluid to a new dust seal lip.

Do not tap the oil Install the dust seal until it is fully seated on the fork
seal lip too hard. slider.
DUST SEAL
Pour the specified amount of fork fluid into the fork pipe.
FORK FLUID CAPACITY:

79.0 ± 2.0 cm3 (2.67 ± 0.07 US oz, 2.78 ± 0.07 Imp oz)
Slowly pump the fork pipe several times to remove
trapped air from the lower portion of the fork pipe.
Be sure the oil level Compress the fork pipe fully and measure the oil level
is same in the both from the top of the fork pipe.
forks.
FORK OIL LEVEL: 59 mm (2.3 in)
13-20
dummyhead
Pull the fork pipe up fully.
Install the fork spring into the fork pipe with its narrow
pitched end facing down.
FORK SPRING
Coat a new O-ring with fork fluid and install it into the
groove on the fork cap bolt. FORK CAP BOLT
O-RING
Install the fork cap bolt, but tighten it after installing it to
the steering stem.
INSPECTION
FORK SPRING
Check the fork spring for fatigue or damage.
Measure the fork spring free length.
FORK PISTON
Check the fork piston for score marks and excessive or
abnormal wear. FORK PISTON
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.
Replace the components if necessary.
FORK PISTON RING

REBOUND SPRING
13-21
dummyhead
FORK PIPE/FORK SLIDER
Check the fork pipe and fork slider for score marks and
excessive or abnormal wear. FORK PIPE
Replace the components if necessary.
FORK SLIDER
Set the fork pipe in V-block and measure the runout

with a dial gauge. DIAL GAUGE
Actual runout is 1/2 the total indicator reading.
FORK PIPE
Visually inspect the guide bushing in the fork slider.

Replace the fork slider if there is excessive scoring or BACK-UP RING
scratching, or if the teflon is worn so that the copper GUIDE BUSHING
surface appears on more than 3/4 of the entire surface.
Check the back-up ring; replace it if there is any
distortion at the points shown.
CHECK POINTS
HANDLEBAR
REMOVAL
BRAKE MASTER
– Front handlebar cover (page 2-8) CYLINDER
– Rear handlebar cover (page 2-9)
BRAKE MASTER CYLINDER (EXCEPT MX TYPE)
Keep the brake Remove the bolts, holder and brake master cylinder.
master cylinder
upright to prevent
air from entering the
system.
Do not twist the
brake hose.
HOLDER BOLTS
13-22
dummyhead
THROTTLE HOUSING (EXCEPT MX TYPE)
Remove the screws and upper throttle housing.
SCREWS UPPER HOUSING
Disconnect the throttle cable from the throttle pipe and
remove the lower throttle housing. THROTTLE PIPE
Remove the throttle pipe from the handlebar.
THROTTLE CABLE LOWER HOUSING
THROTTLE HOUSING/BRAKE LEVER BRACKET

(MX TYPE)
Remove the bolt and upper throttle housing.
BOLT UPPER
Disconnect the throttle cable from the throttle pipe and HOUSING
remove the lower throttle housing/brake lever bracket.
THROTTLE
Remove the throttle pipe from the handlebar. CABLE THROTTLE
PIPE
LOWER HOUSING
REAR BRAKE LEVER BRACKET (MX TYPE)

Hold the rear brake lever bracket and remove the
holder bolt. BRACKET HOLDER
Remove the bracket holder and the brake lever bracket.
BOLT
BRAKE LEVER BRACKET
HANDLEBAR GRIP
Remove the handlebar grip.
HANDLEBAR GRIP
13-23
dummyhead
HANDLEBAR POST
Release the cables from the handlebar post clamp.
Remove the handlebar post nut, bolt, collars and STEERING
handlebar post from the steering stem. STEM LEFT
RIGHT
COLLAR
COLLAR
INSTALLATION
HANDLEBAR POST BOLT
Install the handlebar post onto the steering stem while

aligning the holes of the steering stem and handlebar
post.
Apply engine oil to the handlebar post nut.
BOLT/COLLAR
Front
The bolt side collar Install the bolt, collars and nut as shown.
is taller than nut
Tighten the nut to the specified torque.
side collar.
NUT
Route the cables Secure the cables with the handlebar clamp.
properly (page 1-
13).
CLAMP NUT/COLLAR
HANDLEBAR GRIP
Apply Honda Bond A or equivalent to the inside of the
grip and to the clean surfaces of the left handlebar. HANDLEBAR GRIP
Allow the adhesive Wait 3 – 5 minutes and install the grip.
to dry for 1 hour Rotate the grip for even application of the adhesive.
before using.
13-24
dummyhead
REAR BRAKE LEVER BRACKET (MX TYPE)
Install the rear brake lever bracket by aligning the hole
on the handlebar with the locating pin of the rear brake
lever bracket.
Hook the bracket holder to the tab of the rear brake
lever bracket while holding the brake lever bracket. BOLT
BRACKET HOLDER
Install and tighten the brake lever bracket holder bolt.
TAB
HOLE
PIN
BRAKE LEVER BRACKET
THROTTLE HOUSING (EXCEPT MX TYPE)

Install the throttle pipe to the right handlebar.
THROTTLE PIPE
Apply grease to the throttle cable sliding area and
connect the throttle cable to the throttle pipe.
Install the lower throttle housing by aligning the hole on
the handlebar with the locating pin of the lower throttle
housing.
THROTTLE CABLE
Align LOWER HOUSING
Install the upper throttle housing onto the lower

housing. UPPER HOUSING SCREWS
Install the screws and tighten the forward screw first,
then the rear screw.
13-25
dummyhead
BRAKE MASTER CYLINDER (EXCEPT MX TYPE)
Set the brake master cylinder to the right handlebar.
BRAKE MASTER
Install the master cylinder holder with its "UP" mark
CYLINDER
facing up.
Align the end of the master cylinder with the punch
mark on the handlebar and tighten the upper bolt first,
then tighten the lower bolt to the specified torque.
Check the combined brake system (page 3-13).
"UP" MARK BOLTS PUNCH MARK
THROTTLE HOUSING/BRAKE LEVER BRACKET

(MX TYPE)
Install the throttle pipe to the right handlebar.
Apply grease to the throttle cable sliding area and
connect the throttle cable to the throttle pipe.
BOLT
Install the lower throttle housing/brake lever by aligning
the hole on the handlebar with the locating pin of the
lower throttle housing/brake lever. THROTTLE
PIPE UPPER
Hook the upper throttle housing to the tab of the lower HOUSING
housing/brake lever bracket while holding the lower
housing/brake lever bracket.
Install and tighten the bolt.
THROTTLE
– Rear handlebar cover (page 2-9) CABLE
– Front handlebar cover (page 2-8)
TAB
Align
LOWER HOUSING
13-26
dummyhead
STEERING STEM
REMOVAL
Except MX type:
– Fork (page 13-14)
– Handlebar (page 13-22) Front
STEM
EXCEPT MX TYPE
Remove the brake hose clamp bolt and clamp. GUIDE Right
Release the speedometer cable from the cable guide.
MX TYPE
SPEEDOMETER
Remove the brake cable and speedometer cable from CABLE
the guide. CLAMP
BOLT
Left
STEM BRAKE HOSE
MX type:
Front
STEM
Left
GUIDE
BRAKE CABLE SPEEDOMETER

CABLE
Loosen the steering stem lock nut using the socket

wrench. SOCKET WRENCH
TOOL:
Socket wrench 07916-KM10000
Remove the steering stem lock nut and lock washer.
LOCK NUT/
LOCK WASHER
Hold the steering stem and remove the adjusting nut/

upper inner race. NUT/UPPER INNER RACE
Remove the upper bearing.
UPPER BEARING
13-27
dummyhead
Remove the lower bearing and steering stem.
STEERING STEM LOWER BEARING
Always replace the Install the adjustable remover head into the upper outer
bearings and races race. REMOVER ADJUSTING NUTS
as a set. HEAD
Hold the upper outer race with adjustable remover head
hooks by turning its adjusting nuts, making sure it is
installed correctly.
Remove the upper outer race from the steering stem
pipe.
TOOLS:
Adjustable remover head 07JAC-PH80100
Adjustable remover shaft 07JAC-PH80200
Remover weight 07741-0010201 HOOKS
UPPER OUTER RACE
REMOVER
WEIGHT
REMOVER
SHAFT
UPPER OUTER RACE
Remove the lower outer race using the following tools.

REMOVER LOWER OUTER RACE
TOOLS: HEAD
Adjustable remover head 07JAC-PH80100
Adjustable remover shaft 07JAC-PH80200
REMOVER
WEIGHT
REMOVER SHAFT
13-28
dummyhead
Remove the dust seal from the steering stem.
LOWER INNER RACE DUST SEAL
Remove the lower inner race with a chisel or equivalent
tool being careful not to damage the stem.
Remove the washer from the steering stem.
WASHER
INSTALLATION
LOCK NUT
LOCK WASHER
LOWER OUTER RACE ADJUSTING NUT/

UPPER INNER RACE
LOWER BEARING
UPPER BEARING
LOWER INNER RACE
UPPER OUTER RACE
DUST SEAL
WASHER
GREASE with extreme pressure agent (recommended:

STEERING STEM EXCELIGHT EP2 manufactured by KYODO YUSHI, japan or
Shell ALVANIA EP2 or equivalent)
Install the washer to the steering stem.

Install a new lower inner race using the following tool WASHER
Do not damage the
bearing rolling area and hydraulic press.
of the lower inner
race.
TOOL:
Inner driver, 30 mm 07746-0030300
LOWER INNER RACE INNER DRIVER
13-29
dummyhead
Install a new dust seal to the lower inner race groove.
Apply grease with extreme pressure agent
(recommended: EXCELIGHT EP2 manufactured by
DUST SEAL
KYODO YUSHI, japan or Shell ALVANIA EP2 or
equivalent) to the dust seal lip.
Drive a new upper outer race into the head pipe using
the following tools. ATTACHMENT
TOOLS:
DRIVER
Driver 07749-0010000
Attachment, 44 x 49.5 mm 07945-3330300
UPPER OUTER RACE
Drive a new lower outer race into the head pipe using
LOWER OUTER RACE
the following tools.
TOOLS:
Driver 07749-0010000
Attachment, 44 x 49.5 mm 07945-3330300
DRIVER
ATTACHMENT
Apply 3 – 5 g of grease with extreme pressure agent

(recommended: EXCELIGHT EP2 manufactured by
equivalent) to lower inner race, lower bearing and lower
outer race.
Install the lower bearing onto the steering stem.
STEERING STEM LOWER BEARING
13-30
dummyhead
Apply 3 – 5 g of grease with extreme pressure agent
(recommended: EXCELIGHT EP2 manufactured by ADJUSTING NUT/UPPER INNER RACE
equivalent) to upper inner race, upper bearing and
upper outer race.
Insert the steering stem into the steering head pipe.
Install the upper bearing onto the stem.
Install the steering stem adjusting nut/upper inner race
onto the steering stem.
UPPER BEARING
Tighten the steering stem adjusting nut/upper inner

race to the specified torque. ADJUSTING NUT WRENCH
TOOL:
Adjusting nut wrench 07SMA-GBC0100
ADJUSTING NUT/UPPER INNER RACE
Turn the steering stem lock-to-lock several times to

seat the bearing.
Check the steering head bearing by moving the
steering stem forward and backward.
Temporarily loosen the steering stem adjusting nut/

upper inner race completely.
Tighten the adjusting nut/upper inner race fully by hand,
then loosen it 45°.
ADJUSTING NUT/UPPER INNER RACE
13-31
dummyhead
Install the lock washer by aligning the tab of the lock
washer and groove of the steering stem. LOCK NUT
Install the steering stem lock nut.
LOCK
WASHER
Align
Tighten the steering stem lock nut to the specified

torque. SOCKET WRENCH
TOOL:
Socket wrench 07916-KM10000

Turn the steering stem lock-to-lock several times to
seat the bearing.
Make sure the steering stem moves smoothly without
play or binding.
LOCK NUT
EXCEPT MX TYPE
Route the speedometer cable through the cable guide.
Set the brake hose clamp and tighten the bolt.
Except MX type:
MX TYPE
Route the speedometer cable and front brake cable Front
through the cable guide. STEM
Install the following: GUIDE

– Fork (page 13-14) Right
– Handlebar (page 13-24) SPEEDOMETER
CABLE
CLAMP
BOLT
Left
STEM BRAKE HOSE
MX type:
STEM Front
Left
GUIDE
SPEEDOMETER
BRAKE CABLE CABLE
13-32
dummytext
14. REAR WHEEL/SUSPENSION
COMPONENT LOCATION ··························14-2 REAR WHEEL············································· 14-4
SERVICE INFORMATION ···························14-2 REAR SHOCK ABSORBER ······················· 14-5
TROUBLESHOOTING·································14-3
14
14-1
dummyhead
COMPONENT LOCATION
118 N·m (12.0 kgf·m, 87 lbf·ft)
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake shoe dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• When servicing the rear wheel and suspension, support the scooter using a safety stand or hoist.
• Use only tires marked "TUBELESS" and tubeless valve stems on rims marked "TUBELESS TIRE APPLICABLE".
• Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points.
14-2
dummyhead
TROUBLESHOOTING
Rear wheel wobbles
• Bent rim
• Faulty tire
• Axle nut and/or engine mounting bolt not tightened properly
• Loose or worn final gear shaft bearing
• Insufficient tire pressure
Rear wheel turns hard
• Rear brake drag
Soft suspension
• Oil leakage from damper unit
• Weak rear shock absorber spring
Stiff suspension
• High tire pressure
• Bent damper rod
Rear suspension noisy
• Loose mounting fasteners
• Weak rear suspension bushings
• Faulty rear shock absorber
14-3
dummyhead
REAR WHEEL
REMOVAL
Remove the muffler (page 2-13).
Remove the rear axle nut and washer.
Remove the rear wheel.
INSTALLATION
Install the rear wheel onto the final gear shaft by
aligning its splines with the final gear shaft splines.
Install the washer onto the final gear shaft. Align
Apply engine oil to the threads and seating surface of
the rear axle nut.
Install and tighten the rear axle nut to the specified
torque.
Install the muffler (page 2-13).
WASHER
AXLE NUT
INSPECTION
Check the wheel rim runout using dial indicators.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
14-4
dummyhead
REAR SHOCK ABSORBER
UPPER BOLT
– Air cleaner housing (page 5-4)
To avoid damage to Remove the lower mounting bolt from the rear shock
the rear shock absorber.
absorber mounting Remove the upper mounting bolt and rear shock
bolt threads, sightly absorber.
lift the rear wheel.
LOWER BOLT SHOCK ABSORBER
INSPECTION
Check the damper unit for leakage or other damage.
Check the shock absorber bushing for wear or damage. SHOCK ABSORBER
Replace the shock absorber assembly if necessary.
BUSHING
Check the rear shock absorber busing for wear,

deterioration or damage.
BUSHING
14-5
dummyhead
MEMO
dummytext
15. BRAKE SYSTEM
COMPONENT LOCATION ··························15-2 FRONT BRAKE CALIPER

(EXCEPT MX TYPE) ································· 15-13
SERVICE INFORMATION ···························15-3
FRONT BRAKE LEVER
TROUBLESHOOTING·································15-3 (MX TYPE)················································· 15-16
BRAKE FLUID REPLACEMENT/AIR REAR BRAKE LEVER

BLEEDING (EXCEPT MX TYPE) ················15-4 (MX TYPE)················································· 15-17
BRAKE PAD/DISC (EXCEPT MX TYPE)····15-6 BRAKE EQUALIZER

(EXCEPT MX TYPE) ································· 15-17
FRONT BRAKE MASTER CYLINDER
(EXCEPT MX TYPE)····································15-8 FRONT DRUM BRAKE ···························· 15-21
15
REAR DRUM BRAKE ······························· 15-24
15-1
dummyhead
BRAKE SYSTEM
COMPONENT LOCATION
BRAKE SYSTEM
FRONT
12 N·m (1.2 kgf·m, 9 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)

EXCEPT MX TYPE:
34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft)
MX TYPE:
REAR
EXCEPT MX TYPE:
MX TYPE:
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
15-2
dummyhead
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
Frequent inhalation of brake pad and brake shoe dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies. Use and OSHA-approved vacuum cleaner.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful
whenever you remove the reservoir cap; make sure the master cylinder reservoir is horizontal first.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with high
quality brake degreasing agent.
• Check the brake system by applying the brake levers after the air bleeding.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
fluid, they may not be compatible.
• Always check brake operation before riding the scooter.
TROUBLESHOOTING
Poor rear brake performance
• Incorrect adjustment of rear brake lever
• Contaminated brake shoes
• Worn brake shoes
• Worn brake cam
• Worn brake drum
• Improperly installed brake arm
Poor front brake performance (MX type)
• Incorrect adjustment of front brake lever
• Contaminated brake shoes
• Worn brake shoes
• Worn brake cam
• Worn brake drum
• Improperly installed brake arm
Front brake lever soft or spongy (Except MX type)
• Air in hydraulic system
• Leaking hydraulic system
• Contaminated brake pad/disc
• Worn caliper piston seals
• Worn master cylinder piston cups
• Worn brake pad/disc
• Contaminated caliper/master cylinder
• Caliper not sliding properly
• Low brake fluid level
• Clogged fluid passage
Front brake lever hard (Except MX type)
• Clogged/restricted brake system
• Sticking/worn caliper piston/master cylinder piston
• Worn caliper piston seal
• Bent brake lever
Front brake drags (Except MX type)
• Contaminated brake pad/disc
• Misaligned wheel
• Badly worn brake pad/disc
• Warped/deformed brake disc
• Clogged/restricted brake hydraulic system
• Sticking caliper piston
• Improperly adjusted connecting cable
15-3
dummyhead
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING (EXCEPT MX TYPE)
BRAKE FLUID DRAINING
• Avoid spilling brake fluid on painted, plastic or rubber

parts. Place a rag over these parts whenever the
system is serviced.
• Do not allow foreign material to enter the system
when filling the reservoir.
SCREWS
Turn the handlebar until the reservoir is parallel to the RESERVOIR CAP
ground, before removing the reservoir cap.
Remove the screws, reservoir cap, diaphragm plate
and diaphragm from the brake master cylinder.
DIAPHRAGM DIAPHRAGM PLATE
Connect a bleed hose to the front caliper bleed valve.

BLEED VALVE
Loosen the bleed valve and pump the front brake lever
until no more fluid flows out of the bleed valve.
BRAKE FLUID FILLING/AIR BLEEDING

Fill the master cylinder reservoir with DOT 3 or DOT 4
brake fluid from the sealed container to the upper level. RESERVOIR UPPER LEVEL
• Do not mix different types of fluid. They are not

compatible.
• Use only DOT 3 or DOT 4 brake fluid from a sealed
container.
15-4
dummyhead
BRAKE SYSTEM
Connect a commercially available brake bleeder to the
BLEED VALVE
brake caliper bleed valve.
Operate the brake bleeder and loosen the bleed valve.
• Check the fluid level often while bleeding the brakes
to prevent air from being pumped into the system.
Perform the bleeding procedure until the system is
completely flushed/bled.
• If air enters the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
Close the bleed valve and operate the front brake lever.
If it still feels spongy, bleed the system again.
• If the brake bleeder is not available, perform the
following procedure.
Pump up the system pressure with the front brake lever
until there are no air bubbles in the fluid flowing out of
the reservoir small hole and front brake lever resistance
is felt.
Connect a bleed hose to the bleed valve and bleed the
system as follows:
• Check the fluid level often while bleeding to prevent
air from being pumped into the system.
Do not release the 1. Pump the front brake lever several times, then
brake lever until the squeeze the front brake lever all the way and loosen
bleed valve has the bleed valve 1/2 of a turn. Wait several seconds
been closed. and then close the bleed valve.
2. Release the front brake lever slowly and wait several
seconds after it reaches the end of its travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
After bleeding air completely, tighten the brake caliper
BLEED VALVE
bleed valve to the specified torque.
Fill the master cylinder reservoir with DOT 3 or DOT 4

brake fluid from the sealed container to the upper level. RESERVOIR UPPER LEVEL
15-5
dummyhead
BRAKE SYSTEM
Install the diaphragm and diaphragm plate.
SCREWS
Install the reservoir cap and tighten the screws to the RESERVOIR CAP
specified torque.
DIAPHRAGM DIAPHRAGM PLATE
BRAKE PAD/DISC (EXCEPT MX TYPE)

BRAKE PAD REPLACEMENT
Remove the brake pad pin plugs.
Loosen the brake pad pins.
PAD PIN PLUGS PAD PINS
Remove the mounting bolts and remove the brake

caliper from the brake disc. MOUNTING BOLTS
BRAKE CALIPER
BRAKE PADS
Remove the pad pins and brake pads.
BRAKE PADS PAD PIN
15-6
dummyhead
BRAKE SYSTEM
Remove the pad spring.
Clean the inside of the caliper especially around the
caliper pistons.
Install the pad spring as shown.
PAD SPRING
Always replace the Install new brake pads.
brake pads in pairs
Install the pad pins by pushing the pads against the pad
to assure even disc
spring to align the pad pin holes on the pads and
pressure.
caliper.
BRAKE PADS PAD PIN
Install the brake caliper to the left fork by setting the

brake disc between the pads. MOUNTING BOLTS
Install and tighten new brake caliper mounting bolts to
BRAKE CALIPER
Tighten the brake pad pins to the specified torque.

Install and tighten the brake pad pin plugs to the
specified torque.
Operate the front brake lever to seat the caliper pistons
against the pads.
Check the brake operation by applying the front brake
lever.
PAD PINS PAD PIN PLUGS
15-7
dummyhead
BRAKE SYSTEM
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
Replace the brake disc if the smallest measurement is
less than the service limit.
Measure the brake disc warpage.

If the warpage exceeds the service limit, check the
wheel bearings for excessive play.
Replace the brake disc if the wheel bearings are
normal.
FRONT BRAKE MASTER CYLINDER

(EXCEPT MX TYPE)
REMOVAL
Drain the brake fluid (page 15-4).
– Rear handlebar cover (page 2-9) ADJUSTER
Loosen the rear brake adjusting nut until the play of the
rear brake cable becomes maximum (page 3-12).
Loosen the lock nut and turn the adjuster until the play
of the connecting cable becomes maximum.
Disconnect the brake light switch connectors.
CONNECTORS LOCK NUT
Compress the return spring by squeezing the brake

lever. HOLES
Hold the spring by inserting the proper tool through the
holes of the cable holder.
SPRING
15-8
dummyhead
BRAKE SYSTEM
Disconnect the connecting cable end from the knocker
joint. CONNECTING CABLE HOLDER
CABLE END
Remove the return spring from the connecting cable
holder.
Turn the adjuster and remove the connecting cable
from the connecting cable holder.
KNOCKER RETURN SPRING

JOINT JOINT ADJUSTER
Remove the oil bolt, sealing washers and brake hose.

OIL BOLT SEALING WASHERS
BRAKE HOSE
Remove the master cylinder holder bolts, holder and

HOLDER MASTER CYLINDER
master cylinder.
PUNCH MARK
INSTALLATION
Set the master cylinder onto the handlebar.
Install the master cylinder holder with its "UP" mark
facing up.
Align the end of the master cylinder with the punch
mark on the handlebar, and tighten the upper bolt first,
then tighten the lower bolt to the specified torque.
"UP" MARK
BOLTS
Connect the brake hose eyelet and install the oil bolt to
the master cylinder with new sealing washers. OIL BOLT SEALING WASHERS
Push the eyelet joint against the stopper and tighten the
oil bolt to the specified torque.
15-9
dummyhead
BRAKE SYSTEM
Install the connecting cable to the cable holder.
Turn in the adjuster completely. RETURN SPRING ADJUSTER
CABLE HOLDER
Install the return spring into the cable holder.
Compress the return spring by finger and hold the
spring by inserting the proper tool through the holes of
the cable holder.
CONNECTING CABLE
Connect the connecting cable end to the knocker joint

CONNECTING
CABLE END
KNOCKER JOINT
Connect the brake light switch connectors.

Turn the adjuster until the edge surface of the knocker ADJUSTER
seats on the edge surface of the master cylinder body.
KNOCKER CONNECTORS
Check that there is no gap between the knocker pin and

the end of the slot of the knocker joint. KNOCKER PIN
If there is any gap, turn the adjuster until there is no gap
ADJUSTER
knocker joint.
After adjustment, hold the adjuster and tighten the lock
nut to the specified torque.
After tightening the lock nut, check that there is no gap
knocker joint.
Apply rear brake lever several times and check that the KNOCKER JOINT LOCK NUT
distance between the edges has not been changed
after applying the brake.
15-10
dummyhead
BRAKE SYSTEM
Recheck the edge surface of the knocker seats on the
edge surface of the master cylinder body. Inspection
point
Fill and air bleed the hydraulic system (page 15-4).
Adjust the rear brake lever freeplay (page 3-12).
– Rear handlebar cover (page 2-9)
KNOCKER
DISASSEMBLY
– Brake lever pivot nut, pivot screw and return spring
– Brake lever and knocker
– Screw and brake light switch
– Boot
– Snap ring
– Master piston and spring
MASTER PISTON SPRING MASTER CYLINDER

BOOT
SNAP RING
PIVOT SCREW
BRAKE LEVER
RETURN SPRING
PIVOT NUT
KNOCKER SCREW BRAKE LIGHT SWITCH
ASSEMBLY
Replace the piston, Coat the master piston, spring and piston cups with
cups, spring, snap brake fluid. MASTER CYLINDER
ring and boot as a
Install the spring onto the master piston end.
set; do not
substitute individual
parts. CUPS
Do not allow the Install the spring/master piston into the master cylinder.
piston cup lips to
turn inside out.
SPRING
PISTON
15-11
dummyhead
BRAKE SYSTEM
Install the snap ring into the groove of the master
cylinder.
TOOL:
Snap ring pliers 07914-SA50001
SNAP RING
Apply silicon grease to the inside of the boot.

GROOVE
Install the boot into the master cylinder until it is fully SNAP
seated on the snap ring and set its lip into the groove of RING
the master piston.
Apply silicone grease to the brake lever contacting
surface of the master piston.
BOOT
BOOT
Install the brake light switch by aligning the boss of the

switch body and hole of the master cylinder. BRAKE LIGHT SWITCH
Align
Install the brake lever as follows: PIVOT SCREW

Apply silicone grease to the brake lever pivot screw RETURN
rotating surface. SPRING
Install the brake lever and knocker to the master

cylinder.
Set the return spring by hooking its ends on the master
cylinder and the hole of the brake lever.
Install and tighten the brake lever pivot screw to the
specified torque.
Install and tighten the brake lever pivot nut to the PIVOT NUT
specified torque while holding the pivot screw.
BRAKE LEVER KNOCKER
15-12
dummyhead
BRAKE SYSTEM
INSPECTION
Check the piston cups for wear, deterioration or
damage.
Check the master cylinder inner surface and piston
outer surface for scratches or damage.
CUPS
PISTON MASTER CYLINDER
Measure the master cylinder I.D.

Measure the master piston O.D.
FRONT BRAKE CALIPER (EXCEPT MX

TYPE)
REMOVAL
Drain the brake fluid (page 15-4). BOLTS
Disconnect the brake hose from the brake caliper by
removing the oil bolt and sealing washers.
Remove two caliper mounting bolts and the caliper.
Remove the brake pads from the caliper (page 15-6).
INSTALLATION
Install the brake pads to the caliper (page 15-6).
Set the brake caliper onto the left front fork leg. OIL BOLT
Install new caliper mounting bolts and tighten them to
the specified torque. SEALING WASHERS
Connect the brake hose to the brake caliper with the oil
bolt and new sealing washers.
Push the eyelet joint against the stopper and tighten the
oil bolt to the specified torque.
Fill the brake fluid and air bleed the hydraulic brake
system (page 15-4).
15-13
dummyhead
BRAKE SYSTEM
DISASSEMBLY
Remove the following: PIN BOOTS
– Caliper bracket BRACKET
– Pin boots
Place a shop towel over the piston.

Do not use high Position the caliper body with the piston down and
pressure air or bring apply small squirts of air pressure to the fluid inlet to
the nozzle too close remove the pistons.
to the inlet.
Be careful not to Push the dust seals and piston seals in and lift them
PISTON SEALS
damage the piston out.
sliding surface.
Clean the seal grooves, caliper cylinder and piston with
brake fluid.
DUST SEALS
15-14
dummyhead
BRAKE SYSTEM
ASSEMBLY
CALIPER BRACKET
BRACKET PIN BLEED VALVE

BOOT 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
DUST SEAL
PISTON SEAL
BRACKET
PIN BOOT
CALIPER
PISTON
CALIPER BODY
Coat new piston seals with DOT 3 or DOT 4 brake fluid.

Coat new dust seals with silicone grease.
Install the piston seals and dust seals into the seal DUST SEALS
grooves in the caliper cylinders.
Coat the caliper pistons with DOT 3 or DOT 4 brake
fluid and install them into the caliper cylinders with the
opening side facing the pad.
PISTON SEALS
CALIPER
PISTONS
Check the bracket pin boots and replace them if they PIN BOOTS
are deteriorated or damaged.
BRACKET
Apply 0.4 g minimum of silicone grease to the inside of
the pin boots, and install them into the caliper body.
Install the caliper bracket to the caliper body.
15-15
dummyhead
BRAKE SYSTEM
INSPECTION
Check the caliper cylinder for scoring, scratches or
damage.
Measure the caliper cylinder I.D.
Check the caliper piston for scoring, scratches or
damage.
Measure the caliper piston O.D.
FRONT BRAKE LEVER

(MX TYPE)
REMOVAL
Loosen the front brake cable by turning the adjusting SCREW NUT
nut (page 3-11).
Remove the front brake lever pivot screw and nut from
the brake lever bracket.
Release the front brake cable from the brake lever
bracket and disconnect it from the lever.
BRAKE LEVER
BRAKE CABLE
INSTALLATION
Connect the front brake cable to the front brake lever.
Set the front brake lever in position. NUT
Apply grease to the sliding surface of the brake lever SCREW

pivot screw.
Install and tighten the brake lever pivot screw and nut.
Adjust the front brake lever freeplay (page 3-11).
BRAKE LEVER
BRAKE CABLE
15-16
dummyhead
BRAKE SYSTEM
REAR BRAKE LEVER
(MX TYPE)
REMOVAL
Loosen the rear brake cable by turning the adjusting nut SCREW
(page 3-12). COVER
Open the rubber cover.
Remove the rear brake lever pivot screw and nut from
the rear brake lever bracket.
Release the rear brake cable from the rear brake lever
bracket and disconnect it from the lever.
INSTALLATION
Connect the rear brake cable to the rear brake lever.
Set the rear brake lever in position.
Apply grease to the sliding surface of the brake lever
pivot screw.
Install and tighten the brake lever pivot screw to the
specified torque.
NUT
Install and tighten the brake lever pivot nut to the
Close the rubber cover. BRAKE CABLE
Install the front handlebar cover (page 2-8). BRAKE LEVER

Adjust the rear brake lever freeplay (page 3-12).
BRAKE EQUALIZER (EXCEPT MX

TYPE)
REMOVAL
Loosen the connecting cable (page 15-8). SET RUBBER SPECIAL SCREW
Remove the bracket cover special screw and the set

BRACKET COVER
rubber.
Remove two bracket cover screws.
Remove the bracket cover while holding the lock lever.
SCREWS LOCK LEVER
15-17
dummyhead
BRAKE SYSTEM
Be careful when Remove the rear brake lock lever and the return spring.
removing the lock RETURN SPRING
lever. The return
spring may pop out.
LOCK LEVER
Remove the equalizer rod pivot screw and nut.

Remove the rear brake lever pivot screw, nut and brake EQUALIZER ROD BRAKE LEVER
lever. PIVOT SCREW PIVOT SCREW
NUTS
Remove the boot from the rear brake lever bracket and
REAR BRAKE EQUALIZER
equalizer rod.
LIGHT SWITCH
Disconnect the connecting cable and rear brake cable
from the equalizer. REAR BRAKE
CABLE
Disconnect the wire connectors and remove the rear
brake light switch.
BOOT
CONNECTING CABLE
WIRE CONNECTORS
Hold the rear brake lever bracket and remove the bolt,
BOLT
bracket holder and rear brake lever bracket.
REAR BRAKE
BRACKET HOLDER
LEVER BRACKET
15-18
dummyhead
BRAKE SYSTEM
INSTALLATION
BOLT
BRACKET HOLDER
BRAKE LEVER PIVOT SCREW
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
REAR BRAKE
LEVER BRACKET
REAR BRAKE
LIGHT SWITCH
REAR BRAKE CABLE
EQUALIZER
EQUALIZER ROD PIVOT SCREW
BOOT
1 N·m (0.1 kgf·m, 0.7 lbf·ft)
CONNECTING CABLE
BRACKET COVER BRAKE LEVER PIVOT NUT
SCREW 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft) REAR BRAKE LEVER
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)
EQUALIZER ROD PIVOT NUT
RETURN SPRING 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)
SET RUBBER
SPECIAL SCREW
4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) LOCK LEVER
Align the boss of the rear brake lever bracket with the
hole of the handlebar and install the rear brake lever
bracket. BRACKET BOLT
HOLDER
Hook the bracket holder to the tab of the rear brake
lever bracket while holding the brake lever bracket.
Install and tighten the brake lever bracket holder bolt.
TAB
HOLE
BOSS
15-19
dummyhead
BRAKE SYSTEM
Install the rear brake light switch.
REAR BRAKE EQUALIZER
Connect the rear brake light switch wire connectors.
LIGHT SWITCH
Apply grease to the sliding surface of the equalizer. REAR BRAKE
Install the boot over the equalizer rod. CABLE
Connect the rear brake cable to the equalizer with the
"F" mark of the equalizer facing up and set the rear
brake cable to the rear brake lever bracket.
Connect the connecting cable to the equalizer and set
BOOT
the connecting cable to the bracket.
Install the equalizer boot to the rear brake lever bracket. "F" MARK
CONNECTING
WIRE CONNECTORS CABLE
Set the rear brake lever to the brake lever bracket and
equalizer rod. EQUALIZER ROD BRAKE LEVER
PIVOT SCREW PIVOT SCREW
Apply grease to the sliding surface of the brake lever
pivot screw and tighten it to the specified torque.
Install the rear brake lever pivot nut and tighten it to the
Apply grease to the sliding surface of the equalizer rod
pivot screw and tighten it to the specified torque.
TORQUE: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) NUTS
Install and tighten the equalizer rod pivot nut to the
Set the return spring to the brake lock lever.
Install the brake lock lever to the rear brake lever
RETURN SPRING
bracket and make sure that the return spring is set in
position as shown.
LOCK LEVER
Set the bracket cover to the rear brake lever bracket

BRACKET COVER
while holding the lock lever.
Install the two bracket cover screws and tighten them to
SCREWS
15-20
dummyhead
BRAKE SYSTEM
Install the set rubber to the lock lever and tighten the
bracket cover special screw to the specified torque. SET RUBBER SPECIAL SCREW

Adjust the following:
– Connecting cable (page 15-9)
– Rear brake lever freeplay (page 3-12)
– Brake lock operation (page 3-14)
– Rear brake light operation (page 19-9)
FRONT DRUM BRAKE (MX TYPE)

DISASSEMBLY
• Always replace the brake shoes as a set.
• Mark all parts during disassembly so they can be
placed back in the original locations.
BRAKE SHOES
Expand the brake shoes and remove them from the
brake panel.
Remove the brake shoe springs from the brake shoes.
– Nut and bolt
– Brake arm
– Indicator plate
– Return spring
– Brake cam
– Felt seal
– Dust seal
– Speedometer gear SPRINGS
– Shim
DUST SEAL
BRAKE SHOES SPEEDOMETER GEAR
SHIM
BRAKE PANEL
INDICATOR PLATE
BOLT
SHOE SPRINGS
NUT
FELT SEAL
BRAKE CAM
RETURN SPRING
BRAKE ARM
15-21
dummyhead
BRAKE SYSTEM
ASSEMBLY
Apply 2 g of grease to the speedometer gear teeth and
gear rolling contact area. GEAR
Apply grease to a new dust seal lip.
Install the shim, speedometer gear and dust seal to the
brake panel.
SHIM
DUST SEAL
Apply grease to the brake cam sliding surface.

Install the brake cam to the brake panel.
BRAKE CAM
Apply of grease to the felt seal and install it to the brake

panel. SPRING
Install the return spring inserting its end into the brake
panel hole. FELT SEAL
SPRING END/HOLE
Install the indicator plate onto the brake cam by aligning

its wide tooth with the wide groove on the brake cam. INDICATOR PLATE
Align
15-22
dummyhead
BRAKE SYSTEM
Install the brake arm by aligning the punch marks on
the brake arm and brake cam. BOLT NUT
Install the brake arm bolt and tighten the nut.
Align
Apply grease to the anchor pin and brake cam sliding

surfaces. BRAKE SHOES
If the brake shoes Assemble the brake shoes and springs as shown. ANCHOR/
and springs are BRAKE CAM
Install the shoes assembly off the brake cam and
reused, they must
anchor pin.
be placed back in
their original Install the front wheel (page 13-7).
locations.
Adjust the front brake lever freeplay (page 3-11).
SPRINGS
INSPECTION
• For brake shoe inspection (page 3-10).
Measure the front brake drum I.D.
15-23
dummyhead
BRAKE SYSTEM
REAR DRUM BRAKE
DISASSEMBLY
• Always replace the brake shoes as a set.
• Mark all parts during disassembly so they can be
placed back in the original locations.
Remove the rear wheel (page 14-4).
Remove the brake shoes and shoe springs by BRAKE SHOES
expanding the brake shoe springs.
– Adjusting nut and joint pin
– Return spring
– Dust cover
– Bolt and brake arm
– Brake cam
SPRINGS
DUST COVER JOINT PIN
ADJUSTING NUT BRAKE CAM
BRAKE SHOE
BRAKE ARM
BOLT
RETURN SPRING
SPRING
ASSEMBLY
Apply grease to the brake cam sliding surface and
install it to the brake panel.
BRAKE CAM
15-24
dummyhead
BRAKE SYSTEM
Install the brake arm to the brake cam by aligning the
punch marks. Align
BRAKE CAM BRAKE ARM
Install and tighten a new brake arm bolt to the specified

torque. BRAKE ARM
BOLT
Install the dust cover, return spring, joint pin, brake

cable and adjusting nut to the brake arm. JOINT PIN ADJUSTING NUT
DUST COVER RETURN SPRING
Apply grease to the brake cam and anchor pin.

If the brake shoes are reinstalled, check the mark and BRAKE SHOES
make sure that each shoe is reinstalled in its original
position.
Install the shoe springs onto the brake shoes.
Install the brake shoes onto the brake cam and anchor
pin by expanding the brake shoe springs.
Install the rear wheel (page 14-4).
Adjust the rear brake (page 3-12).
SPRINGS
15-25
dummyhead
BRAKE SYSTEM
INSPECTION
• For brake shoe inspection (page 3-10).
Measure the rear brake drum I.D.
15-26
dummytext
16. BATTERY/CHARGING SYSTEM
SYSTEM LOCATION···································16-2 BATTERY ···················································· 16-4
SYSTEM DIAGRAM ····································16-2 CHARGING SYSTEM INSPECTION ·········· 16-5
SERVICE INFORMATION ···························16-3 ALTERNATOR ············································ 16-6
TROUBLESHOOTING·································16-3 REGULATOR/RECTIFIER ·························· 16-6
16
16-1
dummyhead
BATTERY/CHARGING SYSTEM
SYSTEM LOCATION
MAIN FUSE
BATTERY
REGULATOR/RECTIFIER
ALTERNATOR
SYSTEM DIAGRAM
MAIN FUSE 20A

R R
To dimmer
Y
switch
To SE
thermal valve
Y W
G W R Y
Y: Yellow
BATTERY R: Red
G: Green
REGULATOR/RECTIFIER
W: White
ALTERNATOR
16-2
dummyhead
SERVICE INFORMATION
GENERAL
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
– If electrolyte gets on your skin, flush with water.
– If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
– If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician
immediately.
• Always turn off the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
• This model comes with a maintenance free (MF) battery. Remember the following about MF batteries.
– Use only the electrolyte that comes with the battery.
– Use all of the electrolyte.
– Seal the battery properly.
– Never open the seals after installation.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
charge the stored battery every two weeks.
• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
• The battery sealing caps should not be removed. Attempting to remove the sealing caps from the cells may damage the battery.
• The maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged of overcharged or undercharged, or of left to discharge for long period. These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after
2–3 years.
• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out.
For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the
battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does
not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes
down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the scooter.
• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
• When servicing the charging system, always follow the steps in the troubleshooting flow chart (page 16-3).
• For alternator service (page 11-3).
BATTERY CHARGING
• Turn the power ON/OFF at the charger, not at the battery terminal.
• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending
the charging time may damage the battery.
• Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing.
The recommended battery tester puts a “load” on the battery so the actual battery condition can be measured.
Recommended battery tester: BM-210 or BATTERY MATE or equivalent
TROUBLESHOOTING
Unusual condition Probable cause (Check in numerical order)
Battery Battery is damaged or weak 1. Faulty battery
2. Loose or poor contact on related connectors and terminals
3. Current leakage higher than specified value
– Faulty ignition switch
– Shorted wire harness
4. Faulty alternator charging coil
5. Faulty regulator/rectifier
16-3
dummyhead
BATTERY
Always turn the Remove the floor mat (page 2-4).
SCREWS
ignition switch
Remove the two screws and maintenance lid.
"OFF" before
removing the
battery.
MAINTENANCE LID
Disconnect the Remove the terminal bolt and disconnect the negative
negative terminal (–) cable. BATTERY NEGATIVE (-) TERMINAL
first and then the Remove the terminal bolt and disconnect the positive
positive terminal. (+) cable. HOLDER BAND
Release the battery holder band and remove the
battery.
Connect the Install the battery in the reverse order of removal.
positive terminal
After installing the battery, coat the terminals with clean
first and then the
grease.
negative terminal.
POSITIVE (+) TERMINAL
VOLTAGE INSPECTION
Remove the maintenance lid (page 16-4).
Measure the battery voltage using a digital multimeter.
VOLTAGE:
Fully charged: Above 13.0 – 13.2 V
Needs charging: Below 12.3 V
If the battery voltage is below 12.3 V, charge the
battery.
POSITIVE (+) NEGATIVE (–)

TERMINAL TERMINAL
16-4
dummyhead
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
(–) PROBE (+) PROBE
Turn the ignition switch "OFF" and disconnect the
negative (–) battery cable from the battery.
Connect the ammeter (+) probe to the battery (–) cable
and the ammeter (–) probe to the battery (–) terminal.
With the ignition switch "OFF", check for current
leakage.
• When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow the fuse in the tester.
NEGATIVE (–) NEGATIVE (–)
• While measuring current, do not turn the ignition
TERMINAL CABLE
switch "ON". A sudden surge of current may blow
the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 0.5 mA max.
If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION

Be sure the battery is in good condition before
performing this test.
Do not disconnect Warm up the engine to normal operating temperature.
the battery or any Stop the engine, and connect the multimeter as shown.
cable in the
• To prevent a short, make absolutely certain which
charging system
are the positive and negative terminals or cable.
without first
switching off the Restart the engine.
ignition switch. With the headlight on Hi beam, measure the voltage on
Failure to follow this the multimeter when the engine runs at 5,000 min-1
precaution can (rpm).
damage the tester
or electrical
Standard: Measured B V < Measured C V < 15.5 V POSITIVE (+) NEGATIVE (–)
components.
TERMINAL TERMINAL
• B V = battery voltage
• C V = Charging voltage
If the voltage is abnormal, follow the check each item in
the troubleshooting flow chart (page 16-3).
16-5
dummyhead
ALTERNATOR
INSPECTION
It is not necessary Remove the body cover (page 2-6).
to remove the stator
Disconnect the alternator/ignition pulse generator 3P 3P CONNECTOR
coil to make this
connector.
test.
Check the resistance between the following terminals of
the alternator side connector and ground.
STANDARD: White – ground (Charging coil)
0.2 – 1.0 Ω (20°C/68°F)
Yellow – ground (Lighting coil)
0.1 – 0.8 Ω (20°C/68°F)
If readings are far beyond the standard, replace the
alternator stator (page 11-3).
3P CONNECTOR
Y W
REGULATOR/RECTIFIER
Remove the body cover (page 2-6). REGULATOR/
BOLT
Disconnect the regulator/rectifier 4P (Green) connector. RECTIFIER
Remove the mount bolt and regulator/rectifier.
SYSTEM INSPECTION
Disconnect the regulator/rectifier 4P (Green) connector,
and check it for loose contact or corroded terminals.
If the charging voltage (page 16-5) reading is out of
specification, check the regulator/rectifier connector 4P (GREEN) CONNECTOR
terminals (wire harness side) as follows:
Item Terminal Specification
Battery charging line Red (+) and ground (–) Battery voltage should register
Charging coil line White and ground 0.2 – 1.0 Ω at 20° C (68° F)
Lighting coil line Yellow and ground 0.1 – 0.8 Ω at 20° C (68° F)
Ground line Green and ground Continuity should exist
If all components of the charging system are normal

and there are no loose connections at the regulator/
rectifier connectors, replace the regulator/rectifier unit.
16-6
dummytext
17. IGNITION SYSTEM
SYSTEM LOCATION···································17-2 IGNITION SYSTEM INSPECTION ·············· 17-5
SYSTEM DIAGRAM ····································17-2 IGNITION COIL ··········································· 17-7
SERVICE INFORMATION ···························17-3 IGNITION CONTROL MODULE (ICM)········ 17-7
TROUBLESHOOTING·································17-3 IGNITION TIMING ······································· 17-8
PEAK VOLTAGE INSPECTION

PROCEDURE ··············································17-4
17
17-1
dummyhead
IGNITION SYSTEM
SYSTEM LOCATION
IGNITION SYSTEM
MAIN FUSE
IGNITION SWITCH
BATTERY
IGNITION COIL
IGNITION CONTROL
MODULE (ICM)
SPARK PLUG
IGNITION PULSE GENERATOR
SYSTEM DIAGRAM
R: Red
IGNITION Bl: Black
MAIN FUSE SWITCH G: Green
20A Bu: Blue
R R R/Bl Y: Yellow
G Bl/Y
G Bu/Y Bu/Y
R
Bl/Y R/Bl
IGNITION CONTROL IGNITION

BATTERY IGNITION MODULE (ICM)
SPARK PULSE
COIL
PLUG GENERATOR
17-2
dummyhead
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is turned to "ON" and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 17-3.
• The ignition timing cannot be adjusted since the Ignition Control Module (ICM) is factory preset.
• The Ignition Control Module (ICM) may be damaged if dropped. Also, if the connector is disconnected when current is flowing,
the excessive voltage may damage the module. Always turn the ignition switch to "OFF" before servicing.
• A faulty ignition system is often related to poor connected or corroded connectors. Check those connections before proceeding.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
• Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
• For ignition switch inspection, refer to page 19-7.
• For ignition pulse generator removal/installation, refer to page 11-3.
TROUBLESHOOTING
Inspect the following before diagnosing the system.
– Faulty spark plug
– Loose spark plug cap or spark plug wire
– Water got into the spark plug cap (Leaking the ignition coil secondary voltage)
No spark at plug
Unusual condition Probable cause (check in numerical order)
Ignition coil Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/DCV.
primary 2. Cranking speed is too slow. (Battery is undercharged.)
voltage 3. The sampling time of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Poorly connected connectors or an open circuit in the ignition
system.
5. Faulty ignition coil.
6. Faulty ignition control module (ICM) (in case when above No. 1 – 5
are normal).
No peak voltage. 1. Incorrect peak voltage adapter connections
2. Battery is undercharged.
3. Faulty ignition switch
4. Loose or poorly connected ICM connector
5. Open circuit or poor connection in the Red/Black wire of the ICM.
6. Open circuit or poor connection in the Green wire of the ICM.
7. Faulty peak voltage adapter.
8. Faulty ignition pulse generator. (Measure the peak voltage.)
9. Faulty ICM (in case when above No.1 – 8 are normal).
Peak voltage is normal, but no 1. Faulty spark plug or leaking ignition coil secondary current.
spark jumps at the plug. 2. Faulty ignition coil.
Ignition pulse Low peak voltage. 1. The multimeter impedance is too low.
generator 2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling time of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Faulty ignition pulse generator (in case when above No.1 – 3 are
normal).
No peak voltage. 1. Faulty peak voltage adapter.
2. Faulty ignition pulse generator.
17-3
dummyhead
IGNITION SYSTEM
PEAK VOLTAGE INSPECTION
PROCEDURE
• If there is no spark present at the plug, check all
connections for loose or poor contact before
measuring the peak voltage.
• Use a commercially available digital multimeter
(impedance 10 MΩ/DCV minimum).
• The display value differs depending upon the
internal impedance of the multimeter.
• If the Imrie diagnostic tester (model 625) is used,
follow the manufacturer's instruction.
Connect the peak voltage adapter to the digital
multimeter, or use the peak voltage tester. DIGITAL MULTIMETER
TOOL:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor 07HGJ-0020100
with commercially available digital multimeter
(impedance 10 MΩ/DCV minimum)
PEAK VOLTAGE ADAPTOR
When testing the high tension on the ignition coil

secondary side using the peak voltage adaptor, the
inner diode may be damaged. As a damaged adaptor
will cause incorrect peak voltage readings, always
consider a defective adaptor if the peak voltage
readings are all abnormal.
The adaptor diode can be easily checked by the
following procedure.
Therefore, be sure to check the adaptor before
replacing the parts that display an abnormal testing
value.
If you touch the Set the multimeter to the AC voltage range and
adaptor jack measure the local line voltage.
immediately after Then, connect the peak voltage adaptor to the PEAK VOLTAGE ADAPTOR
disconnecting the multimeter, measure the same AC voltage with DC
adaptor, you may voltage range and compare it to AC voltage measured
get electrical shock. previously.
Be sure to
• The adaptor is normal if the DC voltage measured
disconnect the
via the adaptor is about 1.4 times of AC voltage
adaptor after
measured without the adaptor.
allowing the voltage
• The adaptor is defective if the DC voltage measured
to decrease
via the adaptor is 0 V.
sufficiently.
17-4
dummyhead
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
IGNITION COIL PRIMARY
PEAK VOLTAGE
• Check all system connections before inspection. If
the system is disconnected, incorrect peak voltage
might be measured.
• Check cylinder compression and check that the
spark plug is installed correctly.
Support the scooter with its centerstand on a level
surface.
– Center cover (page 2-5)
Disconnect the spark plug cap from the spark plug.
Connect a known-good spark plug to the spark plug cap
and ground the spark plug to the cylinder head as done
in a spark test.
KNOWN-GOOD SPARK PLUG
Pull the dust cover off.

DUST COVER IGNITION COIL
With the ignition coil primary wires connected, connect
the imrie diagnostic tester or peak voltage adaptor
probes to the ignition coil primary terminal and ground.
TOOL:
with commercially available digital multimeter
CONNECTION: Black/Yellow (–) – Ground (+)

Turn the ignition switch "ON" then squeeze the brake CONNECTORS
lever fully.
Avoid touching the Crank the engine with the starter motor and measure (–) PROBE IGNITION COIL
tester probes to the ignition coil primary peak voltage.
prevent electric
shock.
PEAK VOLTAGE: 100 V minimum
If the peak voltage is abnormal, check each item
following the troubleshooting chart (page 17-3).
Connect the spark plug cap to the spark plug.
– Center cover (page 2-5)
(+) PROBE
17-5
dummyhead
IGNITION SYSTEM
IGNITION PULSE GENERATOR PEAK
VOLTAGE
• Check cylinder compression and make sure the
spark plug is installed correctly.
• Check all system connection before inspection. If the
system is disconnected, incorrect peak voltage
might be measured.
Turn the ignition switch to "OFF".
– Maintenance lid (page 16-4)
Disconnect the ignition control module (ICM) 4P
connector.
Connect the peak voltage adapter or tester probes to
the ICM 4P connector.
TOOL:
with commercially available digital multimeter 4P CONNECTOR
PEAK VOLTAGE
CONNECTION: ADAPTOR
Blue/Yellow (+) – Body ground (–) (+)
Turn the ignition switch "ON" and squeeze the brake
lever fully.
Avoid touching the Crank the engine with the starter switch and measure
tester probes to the ignition pulse generator peak voltage. (–)
prevent electric
shock.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at the ICM connector is
abnormal, measure the peak voltage at the alternator/
ignition pulse generator 3P connector. ICM 4P CONNECTOR
Connect the peak voltage tester or adaptor probes to

the connector terminal of the ignition pulse generator 3P CONNECTOR
side.
In the same manner as at the ICM connector, measure
the peak voltage and compare it to the voltage
measured at the ICM connector.
• If the peak voltage measured at the ICM is abnormal
and the one measured at the ignition pulse
generator is normal, the wire harness has an open
or short circuit, or loose connection.
• If both peak voltages measure are abnormal, check
each item in the troubleshooting chart (page 17-3).
• If all items are normal, the ignition pulse generator is
faulty. See following steps for ignition pulse
generator replacement (page 11-3).
removal. (+)
(–)
3P CONNECTOR
17-6
dummyhead
IGNITION SYSTEM
IGNITION COIL
SPARK PLUG WIRE
– Luggage box (page 2-4) SPARK
– Right side cover (page 2-5) PLUG CAP
Disconnect the spark plug cap.
Release the spark plug wire from the guide.
Release the wire band boss from the wire stay.
WIRE BAND BOSS GUIDE
Pull the dust cover off.

DUST COVER CONNECTORS
Disconnect the ignition coil primary connectors.
Remove the mount bolt and ignition coil.
IGNITION COIL BOLT
IGNITION CONTROL MODULE (ICM)

Turn the ignition switch "OFF".
ICM
Disconnect the ICM 4P connector and remove the ICM.
4P CONNECTOR
17-7
dummyhead
IGNITION SYSTEM
SYSTEM INSPECTION
POWER LINE
Turn the ignition switch "ON".
POWER LINE GROUND LINE
Disconnect the ICM 4P connector.
Measure the battery voltage between the ICM 4P ICM 4P CONNECTOR
(Black) connector of the wire harness side and ground.
CONNECTION:
Red/Black (+) – Body ground (–)
There should be battery voltage.
If there is no voltage, check the following: R/Bl
– Wire harness between the ICM and battery
– Ignition switch G
– Fuse
GROUND LINE R
Disconnect the ICM 4P connector.
Check for continuity between the ICM 4P connector of
the wire harness side and ground.
CONNECTION:
Green – Body ground
There should be continuity at all time.
If there is no continuity, check the open circuit in green
wire.
IGNITION TIMING
• The ignition timing is factory preset and need only
be checked when an electrical system component is TIMING HOLE CAP
replaced.
Read the Remove the center cover (page 2-5) and connect the
instructions for timing light to the spark plug wire.
timing light
Remove the timing hole cap.
operation.

Start the engine and let it idle. INDEX NOTCH
The ignition timing is correct if the index notch on the

right crankcase aligns between the "F" mark on the
flywheel as shown.
If the ignition timing is incorrect, inspect the ignition
pulse generator (page 17-6).
removal.
TIMING LIGHT
"F" MARK
17-8
dummytext
18. ELECTRIC STARTER
SYSTEM LOCATION···································18-2 TROUBLESHOOTING ································ 18-3
SYSTEM DIAGRAM ····································18-2 STARTER MOTOR ····································· 18-4
SERVICE INFORMATION ···························18-3 STARTER RELAY······································· 18-7
18
18-1
dummyhead
ELECTRIC STARTER
SYSTEM LOCATION
ELECTRIC STARTER
FRONT BRAKE
REAR BRAKE
LIGHT SWITCH
LIGHT SWITCH
STARTER SWITCH
MAIN FUSE
SUB FUSE
IGNITION SWITCH
STARTER RELAY
BATTERY
STARTER MOTOR
SYSTEM DIAGRAM
R: Red
IGNITION Bl: Black
MAIN FUSE
SWITCH G: Green
20 A
Y: Yellow
R R R/Bl
SUB FUSE
15 A
R R R
Bl
Bl Bl
STARTER FRONT BRAKE REAR BRAKE

RELAY Y/R LIGHT SWITCH LIGHT SWITCH
BATTERY
G
STARTER G/Y
G/Y
MOTOR
G/Y
Y/R G/Y
STARTER
SWITCH
18-2
dummyhead
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
• Always turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting (page 18-3).
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be
damaged.
• Refer to the following component information.
– Starter clutch (page 11-9)
– Ignition switch (page 19-7)
– Starter switch (page 19-8)
– Brake light switch (page 19-8)
TROUBLESHOOTING
Unusual condition Probable cause (Check in numerical order)
Starter motor Starter motor does not turn 1. Loose or poor contact on related connectors and terminals
2. Blown fuse
3. Weak battery
4. Faulty starter relay switch
5. Faulty starter motor
6. Loose connection, open or short circuit in starter motor
cable
7. Faulty brake light switch
8. Faulty starter switch
9. Open circuit in starter relay switch ground circuit
10.Open or short circuit in starter relay switch power circuit
11.Loose contact or open circuit in related wires
Starter motor turns slowly 1. Low battery voltage
2. Poorly connected battery terminal cable
3. Poorly connected starter motor cable
4. Faulty starter motor
5. Poorly connected battery ground cable
Starter motor turns, but engine does 1. Starter motor is running backwards
not turn – Case assembled improperly
– Terminals connected improperly
2. Faulty starter clutch
3. Damaged or faulty starter idle gear and/or reduction gear
Starter relay switch "Clicks", but 1. Crankshaft does not turn due to engine problems
engine does not turn over
18-3
dummyhead
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
Remove the air cleaner housing (page 5-4).
Release the rear brake cable from the guide.
Remove the bolts, ground cable and cable guide.
Remove the starter motor from the engine.
Pull off the cover, then disconnect the starter motor
cable by removing the screw.
Remove the O-ring from the starter motor.
DUST COVER
SCREW
STARTER
MOTOR CABLE
STARTER MOTOR
GROUND CABLE
O-RING
BOLTS GUIDE BRAKE CABLE
INSTALLATION
starter motor groove. STARTER
DUST COVER MOTOR CABLE
Install the starter motor cable and tighten the screw.
Put the dust cover back in the appropriate position.
Install the starter motor to the engine. O-RING
SCREW
STARTER
MOTOR
18-4
dummyhead
ELECTRIC STARTER
Install the bolts, ground cable and cable guide as
shown. GROUND CABLE
BOLTS GUIDE
Set the rear brake cable to the cable guide.

Install the air cleaner housing (page 5-4).
BRAKE CABLE GUIDE
SPRING
SHIM(S) O-RING
ARMATURE
FRONT BRACKET
MOTOR CASE
O-RING
SET PLATE WASHER SCREW
18-5
dummyhead
ELECTRIC STARTER
Install the shim(s) to the armature.
Install the springs to the front bracket.
SHIM ARMATURE
Be careful not to Install the armature into the front bracket while pushing
damage the brush and holding the brushes.
and armature.
SPRINGS
Install a new O-ring in the groove of the front bracket.

Align
The coil may be Install the front bracket and armature to the motor case O-RING
damaged if the by holding the bracket side armature shaft tightly while
magnet pulls the aligning the tabs of the motor case and front bracket.
armature against
the case.
MOTOR CASE ARMATURE
Install the washers, set plates and new O-rings on the

screws. SET PLATES WASHERS
Install the motor case screws and tighten them.
O-RINGS SCREWS
INSPECTION
Inspect the brushes for damage and measure the brush
length.
18-6
dummyhead
ELECTRIC STARTER
Do not use emery Inspect the commutator bars of the armature for
or sand paper on discoloration. COMMUTATOR BARS
the commutator.
Bars discolored in pairs indicate shorted coils.
ARMATURE
Check for continuity between pair of commutator bars.

There should be continuity.
Check for continuity between each commutator bar and

the armature shaft.
There should be no continuity.
STARTER RELAY
NUTS/CABLES RUBBER COVERS
Disconnect the battery negative (-) cable (page 16-4).
Disconnect the starter relay 2P connector.
Remove the rubber covers.
Remove the nuts and cables from the starter relay.
Remove the starter relay.
STARTER RELAY 2P CONNECTOR
18-7
dummyhead
ELECTRIC STARTER
OPERATION INSPECTION
Turn the ignition switch "ON". STARTER RELAY
Squeeze the brake lever fully and push the starter
switch.
The coil is normal if the starter relay clicks.
If you don't hear the relay "CLICK", inspect the starter
relay coil line inspection (page 18-8).
If you hear the relay "CLICK", but starter does not turn,
inspect the starter relay continuity (page 18-9).
STARTER RELAY COIL LINE

INSPECTION
Disconnect the starter relay 2P connector.
Check for continuity between the starter relay connector
of the wire harness side and ground.
CONNECTION: Green – ground
If there is continuity, the circuit is normal.
STARTER RELAY
2P CONNECTOR
TO STARTER
RELAY
STARTER RELAY
2P CONNECTOR
18-8
dummyhead
ELECTRIC STARTER
Squeeze the brake lever fully and push the starter 2P CONNECTOR
switch.
Check the voltage between the starter relay connector From
of the wire harness side and ground. battery
CONNECTION: Yellow/Red (+) – ground (–)

Y/R
If the battery voltage appears only when the ignition
switch is "ON", the circuit is normal.
STARTER
Bl
SWITCH
G/Y Bl
BRAKE LIGHT
SWITCHES
G/Y Bl
STARTER RELAY INSPECTION

Remove the starter relay (page 18-7).
Connect a fully charged 12V battery positive wire to the
relay switch Yellow/Red terminal and negative wire to
the Green wire terminal.
Check for continuity at the starter relay large terminals.
There should be continuity at the large terminals while
the battery is connected, and no continuity when the
battery is disconnected.
STARTER RELAY
18-9
dummyhead
MEMO
dummytext
19. LIGHTS/METER/SWITCHES
SYSTEM LOCATION···································19-2 IGNITION SWITCH······································ 19-7
SERVICE INFORMATION ···························19-2 HANDLEBAR SWITCHES ·························· 19-8
HEADLIGHT ················································19-3 BRAKE LIGHT SWITCH ····························· 19-8
TURN SIGNAL LIGHT·································19-3 FUEL METER ·············································· 19-9
BRAKE/TAIL LIGHT····································19-4 FUEL LEVEL SENSOR····························· 19-10
LICENSE LIGHT··········································19-4 HORN ························································ 19-12
SPEEDOMETER··········································19-5 TURN SIGNAL RELAY ····························· 19-13
19
19-1
dummyhead
LIGHTS/METER/SWITCHES
SYSTEM LOCATION
REAR BRAKE
LIGHT SWITCH
HORN
FRONT BRAKE
LIGHT SWITCH
DIMMER SWITCH
STARTER SWITCH
TURN SIGNAL TURN SIGNAL

SWITCH RELAY
HORN SWITCH
IGNITION SWITCH
FUEL LEVEL SENSOR
SERVICE INFORMATION
GENERAL
• Check the battery condition before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the scooter.
• The following color codes are used throughout this section.
Bu = Blue G = Green Lg = Light green R = Red

Bl = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light blue P = Pink Y = Yellow
19-2
dummyhead
HEADLIGHT
BULB REMOVAL/INSTALLATION
HEADLIGHT
"TOP" MARK DUST COVER
Disconnect the headlight connector from the headlight HEADLIGHT
bulb. CONNECTOR
Remove the dust cover from the headlight unit.
Unhook the headlight bulb retainer.
Remove the headlight bulb from the headlight unit.
Install the headlight bulb by aligning the bulb tabs with
the grooves in the headlight unit.
Hold the headlight bulb and hook the bulb retainer into
the headlight unit groove.
Install the dust Install the dust cover to the headlight unit securely.
cover with its "TOP"
Connect the headlight connector to the headlight bulb.
mark facing up.
Install the front cover (page 2-9).
• For headlight unit removal/installation (page 2-9).
RETAINER HEADLIGHT BULB
POSITION LIGHT
POSITION LIGHT BULB
Pull out the position light bulb socket.
Remove the position light bulb.
BULB SOCKET
TURN SIGNAL LIGHT

FRONT
BULB SOCKET
Remove the front turn signal light bulb socket by turning BULB
counterclockwise.
Remove the front turn signal light bulb by pressing in
and turning counterclockwise.
• For front turn signal unit removal/installation (page
2-9).
19-3
dummyhead
REAR
Remove the screws and rear turn signal light lens.
BULB
Remove the rear turn signal light bulb by pressing in
and turning counterclockwise.
• For rear turn signal unit removal/installation (page 2-
6). LENS
SCREWS
BRAKE/TAIL LIGHT
Remove the rear center lower cover (page 2-5).
BULB
Remove the two screws and rear brake/tail light lens.
Remove the brake/tail light bulb by pressing in and LENS
turning counterclockwise.
• For brake/tail light unit removal/installation (page 2-
6).
SCREWS
LICENSE LIGHT
Except SA type:
Except SA type: BULB SCREWS
Remove the rear center lower cover (page 2-5).
Remove the two screws and license light cover.
Pull out the license light bulb.
SA type:
Pull out the bulb socket from the license light unit and
remove the license light bulb.
LICENSE LIGHT
COVER
SA type:
BULB
BULB SOCKET
19-4
dummyhead
LICENSE LIGHT UNIT REMOVAL/
INSTALLATION (SA TYPE)
WIRE CONNECTORS
Disconnect the license light wire connectors.
Remove the two screws and license light cover/unit
from the rear fender.
LICENSE LIGHT
COVER/UNIT SCREWS
Remove the two screws, license light cover and cover
SCREWS COVER STAY
stay.
Remove the two screws.
Pull out the license light wire from the cover and
remove the license light unit.
LICENSE LIGHT
UNIT
LICENSE LIGHT
COVER
SCREWS
SPEEDOMETER
BULB
Pull the bulb sockets out of the speedometer.
Remove the bulb from the socket.
BULB SOCKET
19-5
dummyhead
SPEEDOMETER REMOVAL/
INSTALLATION
– Front cover (page 2-9) SPEEDOMETER ASSEMBLY
– Front handlebar cover (page 2-8) CONNECTORS
Disconnect the horn wire connectors and brake light

switch wire connectors.
Loosen the speedometer cable nut and disconnect the
cable from the meter.
Disconnect the speedometer 9P connector and release
the sub harness from the clamps, then remove the
speedometer assembly.
METER CABLE NUT

– Bulb sockets and wire connectors
– Three wire terminal screws
– Wire band screw
Connect the wire Installation is in the reverse order of removal.
terminals and install
the sockets as Except MX type shown:
shown in the BULB SOCKET
illustration.
(Lb and G)
BULB SOCKET
(O and G)
BULB SOCKET
(Bu and G)
TERMINAL SCREW/
TERMINAL (Y/W)
WIRE CONNECTOR (Br)
TERMINAL SCREW/
TERMINAL (Bu/W)
WIRE CONNECTOR (G) WIRE BAND TERMINAL SCREW/
SCREW TERMINAL (Bl)
19-6
dummyhead
Disassemble and assemble the speedometer as
following illustration.
METER PANEL
SCREWS
WIRE BAND SCREW
TERMINAL SCREWS
METER LENS
METER/HANDLEBAR
SWITCH WIRE SPEEDOMETER
SCREWS
METER CASE
IGNITION SWITCH
INSPECTION
IGNITION SWITCH
Disconnect the ignition switch 3P connector.
Check for continuity at the terminals of the switch side
connector in each switch position (page 20-2).
3P CONNECTOR
SCREWS IGNITION SWITCH
Disconnect the ignition switch 3P connector.
Remove the mounting screws and ignition switch.
• Replace the mounting screws with new ones.
3P CONNECTOR
19-7
dummyhead
HANDLEBAR SWITCHES
RIGHT HANDLEBAR SWITCH
INSPECTION
Disconnect the starter switch 3P (Black) connector
STARTER SWITCH 3P
(Black) CONNECTOR
LEFT HANDLEBAR SWITCH

INSPECTION
DIMMER SWITCH
Pull the switch cover off. 3P CONNECTOR
Disconnect the following: TURN SIGNAL SWITCH
– Dimmer switch 3P connector 3P (Red) CONNECTOR
– Turn signal switch 3P (Red) connector
– Horn switch 3P (Black) connector
HORN SWITCH 3P
(Black) CONNECTOR
BRAKE LIGHT SWITCH

FRONT BRAKE LIGHT SWITCH
The brake light Check that the brake light comes on just prior to the
switch on the brake brake actually being engaged.
lever cannot be
If the brake light switch actuation and brake
adjusted.
engagement are off, inspect the brake light switch.
Disconnect the brake light switch connectors or wire
connectors (Green/Yellow and Black) and check for
continuity between the switch side terminals.
There should be continuity with the front brake lever
squeezed, and there should be no continuity when the
front brake lever is released.
WIRE CONNECTORS
19-8
dummyhead
REAR BRAKE LIGHT SWITCH
The brake light Check that the brake light comes on just prior to the
switch on the brake brake actually being engaged. WIRE CONNECTORS
lever cannot be
If the brake light switch actuation and brake
adjusted.
engagement are off, inspect the brake light switch.
Disconnect the brake light switch wire connectors
(Green/Yellow and Black) and check for continuity
between the switch side terminals.
There should be continuity with the rear brake lever
squeezed, and there should be no continuity when the
rear brake lever is released.
FUEL METER
METER CIRCUIT INSPECTION
FUEL METER DOES NOT MOVE
Before performing the system inspection, check the
following:
– Battery condition
– Blown fuse
Disconnect the fuel level sensor 3P connector.
Do not leave the Short the fuel level sensor connector terminals of the
terminals wire harness side with the jumper wire.
connected with the
jumper wire for a
CONNECTION: Yellow/White – Green
long time, as it Turn the ignition switch "ON" and check the fuel meter.
causes damage to 3P CONNECTOR
the fuel meter. If the fuel meter gauge moves to "F", it is normal.
• If the above inspection is normal, check the fuel
level sensor (page 19-12).
• If the meter gauge moves to "E" with connector FUEL METER 3P CONNECTOR
shorted, check the following:
– Fuel level sensor wire for open circuit
– Fuel meter black wire for open circuit
IGNITION JUMPER
If the wire harness is normal, replace the speedometer/ SWITCH WIRE
fuel unit with a new one, and recheck. TO MAIN
FUSE
19-9
dummyhead
FUEL METER STAYS AT "F"
Disconnect the fuel level sensor 3P connector (page
19-9).
Check for continuity between the fuel level sensor
connector of the wire harness side and meter terminal.
CONNECTION: Blue/White – Blue/White
• If there is no continuity, there is open circuit in Blue/
White wire.
• If there is continuity, check the fuel level sensor METER TERMINAL
(page 19-12). (Blue/White)
If the fuel level sensor is normal, replace the
speedometer/fuel meter unit with a new one (page
19-6) and recheck.
FUEL LEVEL SENSOR

REMOVAL
FUEL HOSE FUEL AUTO VALVE
Disconnect the fuel hose from the fuel auto valve and VACUUM HOSE
connect a suitable fuel drain hose.
Place a suitable container under the fuel drain hose.
Disconnect the vacuum hose from the fuel auto valve
and connect a commercially available vacuum pump to
the diaphragm vacuum outlet.
Squeeze the vacuum pump and drain fuel from the fuel
tank.
Disconnect the fuel level sensor 3P connector.

WIRE GUIDE 3P CONNECTOR
Release the fuel level sensor wire from the frame clamp
and wire guide.
CLAMP FUEL LEVEL SENSOR WIRE
19-10
dummyhead
Release the fuel level sensor wire from the clamp.
SENSOR WIRE CLAMP
Turn the fuel level sensor holder plate counterclockwise
with a pair of needle nose pliers.
HOLDER PLATE
Remove the fuel level sensor, being careful not to

FUEL LEVEL SENSOR
damage the float arm.
Remove the base packing. GROOVE
INSTALLATION
Check that the base packing is in good condition,
replace if necessary.
Install the fuel level sensor by aligning the groove on
the fuel level sensor with the tab on the fuel tank.
Align TAB
BASE PACKING
Turn the fuel level sensor holder plate clockwise until

SENSOR WIRE
the arrows are aligned. CLAMP
Secure the fuel level sensor wire with the clamp.
HOLDER PLATE ARROWS
19-11
dummyhead
Route the wire Secure the fuel level sensor wire with the frame clamp
WIRE GUIDE 3P CONNECTOR
harness properly and wire guide.
(page 1-13). Connect the fuel level sensor 3P connector.
Install the body cover (page 2-6).
CLAMP FUEL LEVEL SENSOR WIRE
INSPECTION
Remove the fuel level sensor (page 19-10).
FUEL LEVEL SENSOR
Measure the resistance at the connector terminals by
moving the float to upper (full) and lower (empty)
positions.
(20°C/68°F) FULL
CONNECTION FLOAT POSITION
FULL EMPTY
Yellow/White – Green 25 – 45 Ω 400 – 700 Ω
Blue/White – Green 400 – 700 Ω 25 – 45 Ω
Yellow/White – Blue/ 450 – 750 Ω 450 – 750 Ω EMPTY
White
Replace the fuel level sensor if it is out of specification. 3P CONNECTOR
HORN
CONNECTORS
Disconnect the horn connectors from the horn.
Remove the bolt and horn.
INSPECTION
Remove the horn connectors.
Connect a 12 V battery to the horn terminals.
The horn is normal if it sounds when the 12 V battery is
connected to the horn terminals.
HORN BOLT
19-12
dummyhead
TURN SIGNAL RELAY
TURN SIGNAL RELAY
Disconnect the turn signal relay 3P connector from the
relay.
Remove the turn signal relay from the stay.
3P CONNECTOR
INSPECTION
Remove the front cover (page 2-9). TURN SIGNAL RELAY
– Battery condition
– Burned out bulb or non-specified wattage
– Burned fuse
– Ignition switch and turn signal switch function
– Loose connector
Temporarily connect the front turn signal 2P connectors
and headlight 9P (red) connector.
Disconnect the turn signal relay 3P connector from the
relay.
Short the turn signal relay terminals of the turn signal 3P CONNECTOR CONNECTORS
relay connector with a jumper wire.
CONNECTION: Black – Gray JUMPER WIRE
Turn the ignition switch "ON" and check the turn signal 3P CONNECTOR
light.
If the light comes on, the turn signal relay is faulty.
To IGNITION
If the light does not come on, there is open circuit in SWITCH
wire harness.
TURN SIGNAL SWITCH
19-13
dummyhead
MEMO
dummytext
20. WIRING DIAGRAM
WIRING DIAGRAM······································20-2
20
20-1
FRONT BRAKE
LIGHT SWITCH
REAR
EXCEPT BRAKE
20-2
MX: MX: LIGHT STARTER STARTER
SWITCH SWITCH
RIGHT FRONT
SL
BAT
RELAY
SL
BAT
FUEL LEVEL
TURN SIGNAL LIGHT IGNITION SENSOR
GROUND
SL
BAT
(12V21W) SWITCH
2P
ST
12V6AH
E
Lb Lb E
Bl
G G BATTERY
3P
BAT1
BAT2
CDI
F
Bl
Bl
Bl
G/Y
Bl
G/Y
G/Y
dummyhead
TURN 3P 2P
WIRING DIAGRAM
Bl
G
Y/W
Y/R
Bu/W
SIGNAL
G/Y
3P
WIRING DIAGRAM
R
RELAY Gr
R
G
3P
Bl
Bl
Y/R
R/Bl
G/Y
G/Y
HEADLIGHT
(12V35W/35W) 2P
Bl Bl
Gr Gr
G
Y/W
Bl
R
G G G
Bu/W
WIRING DIAGRAM
Bu Bu Bu
W W W SUB MAIN
9P
R
Bl Bl
FUSE FUSE
POSITION 15A 20A
LIGHT G
R
(12V5W) Bl
R/Bl
RIGHT REAR
SPEEDOMETER TURN SIGNAL LIGHT
(12V21W)
Br Br Lb
INSTRUMENT
LIGHT G G G
Bl
3P
Lb
FUEL G BRAKE/TAIL LIGHT

METER Bu/W
Bu/W Bu/W (12V21W/5W)
Y/W Y/W Y/W
3P
Y Y Bl Bl
Bl Bl Bl G G
9P
RIGHT TURN G/Y G/Y G/Y G/Y
SIGNAL INDICATOR Lb Lb Lb
12V3.4W G G G
Y/R Y/R
LEFT TURN O O O
SIGNAL INDICATOR G
12V3.4W EXCEPT SA:
HI BEAM INDICATOR Bu
G Bl
12V3.4W G LICENSE
LIGHT
SA: (12V5W)
G G
2P Bl Bl
O O
Y
W
Br
Y
Bu/Y
G G
G/Bl
2P
R
LEFT FRONT R 3P
3P
O
Y
R
G
W
TURN SIGNAL LIGHT

(12V21W) G
Y
Y
W
G/Bl
G/Bl
G
Bu/Y
O
4P
G
Bl/Y
O
G
Bl
W
Lg
Gr
Lb
Lg
Bu
SE
THERMAL LEFT REAR TURN
G
Bl/Y
R/Bl
Bl R
Bu/Y
SIGNAL LIGHT
G
3P 3P 3P
VALVE
REGULATOR/ (12V21W)
R
HL
RECTIFIER 4P
IGNITION
THERMAL IGNITION COIL
HO
WR
L
LO
HI
VALVE PULSE
BAT1
RESISTER GENERATOR
HORN TURN DIMMER HORN
SWITCH SIGNAL SWITCH ALTERNATOR IGNITION
CONTROL SPARK
SWITCH PLUG
MODULE
IGNITION SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH STARTER SWITCH
BAT1 BAT2 HL Lo Hi R WR L Ho BAT1 ST E
Bl Black Br Brown
LOCK LO R FREE FREE Y Yellow O Orange
OFF N N PUSH PUSH Bu Blue Lb Light blue
ON Hi L COLOR Lg Bl COLOR G/Y Y/R1 G Green Lg Light green
COLOR R1 R/Bl COLOR Y W Bu COLOR Lb Gr O R Red P Pink

W White Gr Gray
COLOR COMB : GROUND / MARKING
dummytext
21. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR PERFORMANCE AT

HARD TO START········································21-2 HIGH SPEED··············································· 21-6
ENGINE LACKS POWER ···························21-3 POOR HANDLING ······································ 21-6
POOR PERFORMANCE AT LOW AND

IDLE SPEED················································21-5
21
21-1
dummyhead
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
TROUBLESHOOTING
1. Spark Test
Perform spark test.
Is there weak or no spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Broken or shorted spark plug wire
• Faulty ignition coil
• Faulty ignition pulse generator
• Faulty ignition switch
• Faulty ignition control module (ICM)
NO – GO TO STEP 2.
2. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug wet?
YES – • Flooded carburetor
• Throttle valve open
• Dirty air cleaner
• Improperly adjusted pilot screw
3. Fuel Line Inspection
Check fuel flow to carburetor.
Does fuel reach the carburetor?
NO – • Clogged fuel hose or fuel strainer
• Clogged fuel valve
• Clogged fuel tank cap breather hole
YES – GO TO STEP 4.
4. Starting Enrichment (SE) Thermal Valve
Let the engine cool down for 30 minute or more, then insert a vinyl hose into the fuel enrichment circuit and
blow into the hose.
Does the air flow into the circuit.?
NO – Faulty starting enrichment (SE) thermal valve
5. Cylinder Compression
Test cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper valve timing
6. Engine Starting Condition
Start the engine by following normal procedure.
Does the engine start then stops?
YES – • Faulty starting enrichment (SE) thermal valve
• Incorrectly adjusted carburetor
• Leaking carburetor insulator
• Improper ignition timing (Faulty ICM or ignition pulse generator)
• Contaminated fuel
21-2
dummyhead
TROUBLESHOOTING
ENGINE LACKS POWER
1. Rear wheel drag Inspection
Raise wheel off the ground and spin by hand.
Does the wheel spin freely?
NO – • Brake dragging
• Worn or damaged final reduction bearings
2. Tire Pressure Inspection
Check tire pressure.
Are the tire pressures low?
YES – • Faulty tire valve
• Punctured tire
3. Drive Train Inspection
Accelerate rapidly.
Does the engine speed change accordingly?
NO – • Clutch slipping
• Worn clutch shoes/outer
• Weak driven face spring
• Weight roller stuck
• Additive in engine oil
4. Engine Condition Inspection
Accelerate lightly.
Does the engine speed increase?
NO – • Fuel/air mixture too rich or lean
• Clogged air cleaner
• Restricted fuel flow
• Clogged muffler
• Clogged fuel tank cap breather hole
5. Engine Performance Inspection
Accelerate or run at high speed.
Is there knocking?
YES – • Worn piston and cylinder
• Use of poor quality fuel
• Excessive carbon build-up in combustion chamber
• Ignition timing too advance (Faulty ICM)
• Lean fuel mixture
6. Ignition Timing Inspection
Check ignition timing.
Is the ignition timing correct?
NO – • Faulty ignition control module (ICM)
21-3
dummyhead
TROUBLESHOOTING
7. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug fouled or discolored?
YES – • Plugs not serviced frequently enough
• Incorrect spark plug used
• Incorrect spark plug gap
8. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor for clogged?
YES – Carburetor not serviced frequently enough
9. Cylinder compression Inspection
Test the cylinder compression.
Is the compression low?
YES – • Valve clearance too small
• Valve stuck open
• Worn cylinder and piston rings
• Damaged head gasket
10. Engine Oil Inspection
Check oil level and condition.
Is there correct level and good condition?
NO – • Oil level too high
• Oil level too low
• Contaminated oil
11. Lubrication Inspection
Remove cylinder head cover and inspect lubrication.
Is the valve train lubricated properly?
NO – • Clogged oil passage
• Clogged oil strainer
21-4
dummyhead
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Pilot Screw Inspection
Check carburetor pilot screw adjustment.
Is the adjustment correct?
NO – See page 5-22
2. Intake Air Leak Inspection
Check for leaking carburetor insulator.
Is there leaking?
YES – • Loose carburetor insulator bands
• Damaged insulator
3. Starting Enrichment (SE) Thermal Valve
Inspect the starting enrichment (SE) thermal valve (page 5-19).
Does the starting enrichment (SE) thermal valve operate normally?
NO – Faulty starting enrichment (SE) thermal valve
4. Spark Test
Perform spark test.
Is there weak or intermittent spark?
YES – • Faulty spark plug
• Fouled spark plug
• Loose or disconnected ignition system wires
• Broken or shorted spark plug wire
• Faulty ignition coil
• Faulty ignition control module (ICM)
21-5
dummyhead
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
1. Fuel Line Inspection
Disconnect fuel line at carburetor and vacuum the fuel auto valve (page 5-25).
Does fuel flow freely?
NO – • Clogged fuel line
• Clogged fill cap breather
• Faulty fuel auto valve
• Clogged fuel strainer
2. Carburetor Inspection
Check carburetor for clogging.
Is the carburetor clogged?
YES – Carburetor not serviced frequently enough
4. Valve Timing Inspection
Check valve timing.
Is the valve timing correct?
NO – Cam sprocket not installed properly
5. Valve Spring Inspection
Check valve springs.
Are the valve springs weak?
YES – Faulty valve spring
POOR HANDLING
Steering is heavy
• Steering bearing adjustment nut too tight
• Damaged steering head bearings
Either wheel is wobbling
• Excessive wheel bearing play
• Bent rim
• Improperly installed wheel hub
• Excessively worn engine mounting bushings
• Bent frame
Scooter pulled to one side
• Front and rear wheels not aligned
• Bent fork
• Faulty shock absorber
• Bent axle
• Bent frame
21-6
INDEX
dummytext
INDEX
AIR CLEANER ································································3-4 FLOOR MAT··································································· 2-4
A
AIR CLEANER HOUSING ··············································5-4 FLOOR PANEL ······························································ 2-8

ALTERNATOR ······························································16-6 FLYWHEEL/STATOR··················································· 11-3
BATTERY······································································16-4 FORK·········································································· 13-14
B
BODY COVER ································································2-6 FRONT BRAKE CALIPER (EXCEPT MX TYPE) ······· 15-13
BODY PANEL LOCATIONS ···········································2-2 FRONT BRAKE LEVER (MX TYPE) ·························· 15-16
BODY PANEL REMOVAL CHART ·································2-2 FRONT BRAKE MASTER CYLINDER
BRAKE EQUALIZER (EXCEPT MX TYPE) ················15-17 (EXCEPT MX TYPE) ···················································· 15-8
BRAKE FLUID (EXCEPT MX TYPE) ····························3-10 FRONT COVER······························································ 2-9
BRAKE FLUID REPLACEMENT/AIR BLEEDING FRONT DRUM BRAKE (MX TYPE) ··························· 15-21
(EXCEPT MX TYPE)·····················································15-4 FRONT FENDER·························································· 2-12
BRAKE LIGHT SWITCH ···············································19-8 FRONT HANDLEBAR COVER······································· 2-8
BRAKE LOCK OPERATION ·········································3-14 FRONT INNER COVER ··············································· 2-11
BRAKE PAD/DISC (EXCEPT MX TYPE) ·····················15-6 FRONT LOWER COVER ············································· 2-12
BRAKE SHOES WEAR (MX TYPE) ·····························3-10 FRONT WHEEL···························································· 13-5
BRAKE SHOES/PADS WEAR (EXCEPT MX TYPE) ···3-11 FUEL AUTO VALVE ····················································· 5-24
BRAKE SYSTEM ··························································3-11 FUEL LEVEL SENSOR ·············································· 19-10
BRAKE/TAIL LIGHT······················································19-4 FUEL LINE ····································································· 3-3
CABLE & HARNESS ROUTING ···································1-13 FUEL METER ······························································· 19-9
C
CAM CHAIN TENSIONER LIFTER·······························7-20 FUEL TANK ·································································· 5-23

CAMSHAFT/CYLINDER HEAD ······································7-6 HANDLEBAR······························································ 13-22
H
CARBURETOR ASSEMBLY·········································5-13 HANDLEBAR SWITCHES············································ 19-8

CARBURETOR CLEANING··········································5-19 HEADLIGHT ································································· 19-3
CARBURETOR DISASSEMBLY·····································5-8 HEADLIGHT AIM·························································· 3-14
CARBURETOR INSPECTION ······································5-19 HORN ········································································· 19-12
CARBURETOR REMOVAL/INSTALLATION··················5-6 IGNITION COIL ···························································· 17-7
I
CENTER COVER····························································2-5 IGNITION CONTROL MODULE (ICM)························· 17-7

CHARGING SYSTEM INSPECTION ····························16-5 IGNITION SWITCH······················································· 19-7
CLUTCH SHOES WEAR ··············································3-15 IGNITION SYSTEM INSPECTION ······························· 17-5
CLUTCH/DRIVEN PULLEY ··········································9-11 IGNITION TIMING ························································ 17-8
COMPONENT LOCATION INLET PIPE ·································································· 5-23
ALTERNATOR/STARTER CLUTCH ························11-2 INTAKE/EXHAUST SHROUDS······································ 7-5
BRAKE SYSTEM······················································15-2 KICKSTARTER····························································· 9-19
K
CRANKCASE/CRANKSHAFT ··································12-2 LEFT CRANKCASE COVER·········································· 9-4

L
CYLINDER HEAD/VALVES ·······································7-2 LICENSE LIGHT··························································· 19-4

CYLINDER/PISTON ···················································8-2 LUBRICATION & SEAL POINTS·································· 1-11
ENGINE REMOVAL/INSTALLATION·························6-2 LUBRICATION SYSTEM DIAGRAM ······························ 4-2
FINAL REDUCTION ·················································10-2 LUGGAGE BOX ····························································· 2-4
FRONT WHEEL/SUSPENSION/STEERING ···········13-2 MAINTENANCE SCHEDULE ········································· 3-2
M
FUEL SYSTEM···························································5-2 MODEL IDENTIFICATION ············································· 1-2

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/ MUFFLER····································································· 2-13
CLUTCH ·····································································9-2 NUTS, BOLTS, FASTENERS······································· 3-15
N
REAR WHEEL/SUSPENSION ·································14-2 OIL PUMP ······································································ 4-4

O
CRANKCASE ASSEMBLY ···········································12-6 OIL PUMP DRIVE CHAIN ·············································· 4-4

CRANKCASE BREATHER ·············································3-4 PEAK VOLTAGE INSPECTION PROCEDURE ··········· 17-4
P
CRANKCASE SEPARATION········································12-4 PILOT SCREW ADJUSTMENT···································· 5-22

CRANKSHAFT INSPECTION·······································12-9 PISTON ·········································································· 8-4
CYLINDER ······································································8-3 POOR HANDLING························································ 21-6
CYLINDER COMPRESSION TEST································7-4 POOR PERFORMANCE AT HIGH SPEED ················· 21-6
CYLINDER HEAD COVER ·············································7-4 POOR PERFORMANCE AT LOW AND IDLE
DRIVE BELT SPEED ········································································· 21-5
D
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/ REAR BRAKE LEVER················································ 15-17

R
22
CLUTCH ·····································································9-7 REAR CARRIER····························································· 2-4
MAINTENANCE ·························································3-8 REAR CENTER LOWER COVER ·································· 2-5
DRIVE PULLEY ······························································9-7 REAR DRUM BRAKE················································· 15-24
EMISSION CONTROL SYSTEMS································1-25 REAR FENDER ···························································· 2-12
E
ENGINE ··········································································6-3 REAR HANDLEBAR COVER ········································· 2-9

ENGINE DOES NOT START OR IS HARD TO REAR SHOCK ABSORBER ········································· 14-5
START ··········································································21-2 REAR WHEEL ······························································ 14-4
ENGINE HANGER BRACKET ········································6-9 REGULATOR/RECTIFIER ··········································· 16-6
ENGINE IDLE SPEED ····················································3-8 RIGHT CRANKCASE COVER ····································· 11-6
ENGINE LACKS POWER ·············································21-3 RIGHT CRANKSHAFT BEARING REPLACEMENT ···· 12-8
ENGINE OIL····································································3-7 SEAT ············································································ 2-13
S
ENGINE OIL STRAINER SCREEN ································3-8

FINAL DRIVE OIL ···························································3-9
F
FINAL REDUCTION BEARING REPLACEMENT ········10-7

FINAL REDUCTION CASE ASSEMBLY ······················10-4
FINAL REDUCTION CASE SEPARATION···················10-3
FINAL REDUCTION INSPECTION·······························10-5
22-1
dummytext
INDEX
SERVICE INFORMATION SYSTEM DIAGRAM
ALTERNATOR/STARTER CLUTCH ······················· 11-2 BATTERY/CHARGING SYSTEM····························· 16-2
BATTERY/CHARGING SYSTEM ···························· 16-3 ELECTRIC STARTER ·············································· 18-2
BRAKE SYSTEM ····················································· 15-3 IGNITION SYSTEM·················································· 17-2
CRANKCASE/CRANKSHAFT ································· 12-3 SYSTEM LOCATION
CYLINDER HEAD/VALVES······································· 7-3 BATTERY/CHARGING SYSTEM····························· 16-2
CYLINDER/PISTON ·················································· 8-2 ELECTRIC STARTER ·············································· 18-2
ELECTRIC STARTER ············································· 18-3 IGNITION SYSTEM·················································· 17-2
ENGINE REMOVAL/INSTALLATION ························ 6-2 LIGHTS/METER/SWITCHES ··································· 19-2
FINAL REDUCTION ················································ 10-2 THROTTLE OPERATION··············································· 3-3
T
FRAME/BODY PANELS/EXHAUST SYSTEM ·········· 2-3 TORQUE VALUES ························································· 1-7

FRONT WHEEL/SUSPENSION/STEERING··········· 13-4 TROUBLESHOOTING
FUEL SYSTEM ·························································· 5-2 ALTERNATOR/STARTER CLUTCH ························ 11-2
IGNITION SYSTEM ················································· 17-3 BATTERY/CHARGING SYSTEM····························· 16-3
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/ BRAKE SYSTEM ····················································· 15-3
CLUTCH ···································································· 9-3 CRANKCASE/CRANKSHAFT·································· 12-3
LIGHTS/METER/SWITCHES ·································· 19-2 CYLINDER HEAD/VALVES ······································· 7-3
LUBRICATION SYSTEM ··········································· 4-3 CYLINDER/PISTON ··················································· 8-2
MAINTENANCE························································· 3-2 ELECTRIC STARTER ·············································· 18-3
REAR WHEEL/SUSPENSION································· 14-2 FINAL REDUCTION ················································· 10-2
SERVICE RULES··························································· 1-2 FRAME/BODY PANELS/EXHAUST SYSTEM··········· 2-3
SIDE COVER ································································· 2-5 FRONT WHEEL/SUSPENSION/STEERING ··········· 13-4
SIDESTAND (EXCEPT SA TYPE) ······························· 3-15 FUEL SYSTEM ·························································· 5-3
SPARK PLUG································································· 3-5 IGNITION SYSTEM·················································· 17-3
SPECIFICATIONS·························································· 1-3 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/
SPEEDOMETER ·························································· 19-5 CLUTCH ····································································· 9-3
STARTER CLUTCH ····················································· 11-9 LUBRICATION SYSTEM ··········································· 4-3
STARTER IDLE GEAR················································· 11-8 REAR WHEEL/SUSPENSION ································· 14-3
STARTER MOTOR ······················································ 18-4 TURN SIGNAL LIGHT ·················································· 19-3
STARTER RELAY ························································ 18-7 TURN SIGNAL RELAY ··············································· 19-13
STEERING HEAD BEARINGS····································· 3-16 UNDER COVER ····························································· 2-7
U
STEERING STEM ······················································ 13-27 VALVE CLEARANCE ····················································· 3-6

V
SUSPENSION ······························································ 3-15 WHEELS/TIRES ··························································· 3-16

W
WIRING DIAGRAM······················································· 20-2
22-2

Manual de Servicio Elite+ PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual de Servicio Elite+ PDF

Uploaded by

Copyright:

Available Formats

dummyhead

How to use this manual

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

How to use this manual

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

© Honda Motor Co., Ltd.

How to use this manual

Replace the part(s) with new one(s) before assembly.

Use the recommended engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use fork or suspension fluid.

SERVICE RULES ··········································1-2 LUBRICATION & SEAL POINTS ··············· 1-11

MODEL IDENTIFICATION ····························1-2 CABLE & HARNESS ROUTING················· 1-13

SPECIFICATIONS ·········································1-3 EMISSION CONTROL SYSTEMS ·············· 1-25

TORQUE VALUES ········································1-7

V.I.N. (Vehicle Identification Number) ENGINE SERIAL NUMBER

CARBURETOR IDENTIFICATION NUMBER

LUBRICATION SYSTEM SPECIFICATIONS

FUEL SYSTEM SPECIFICATIONS

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

REAR WHEEL/SUSPENSION SPECIFICATIONS

BRAKE SYSTEM SPECIFICATIONS

Front brake Lever freeplay 10 – 20 (0.4 – 0.8) –

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATIONS

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

LUBRICATION & SEAL POINTS

Locking agent Starter clutch socket bolt

LEFT HANDLEBAR DIMMER SWITCH

REAR BRAKE LIGHT TURN SIGNAL LIGHT

IGNITION SWITCH WIRE

METER/HANDLEBAR RESISTOR WIRE

FRONT BRAKE HOSE

REAR BRAKE CABLE

LEFT FRONT TURN

TURN SIGNAL RELAY

MAIN WIRE HARNESS

TURN SIGNAL LIGHT

FRONT BRAKE CABLE

IGNITION SWITCH WIRE

METER/HANDLEBAR RESISTOR WIRE

FRONT BRAKE CABLE

REAR BRAKE CABLE

FRONT BRAKE CABLE

LEFT FRONT TURN

TURN SIGNAL RELAY

MAIN WIRE HARNESS

MAIN WIRE HARNESS

REAR BRAKE CABLE

BATTERY NEGATIVE FRAME GROUND STARTER MOTOR CABLE

MAIN WIRE HARNESS SE THERMAL VALVE WIRE

SA TYPE Shown: ALTERNATOR WIRE

FUEL AUTO VALVE

SPARK PLUG WIRE

MAIN WIRE HARNESS

FUEL AUTO VALVE